slow expedition ranger build

[Devorak]

Ive had my truck for a few years meow, and have taken it out on camping/ wheeling trips a couple dozen times. I plan on making an expedition trail rig that can go where I want and not have to worry about breaking anything. This will be a slow paced build up I'm thinking, because funds are tight I want to do it right the first time.

FUTURE PLANS
-exocage with built in roof top storage that folds open for a roof top tent
-narrowed front dana 60 and rear 10.25
-lockers front and rear
-maybe 5.13 or lower gearing
-onboard air

I just found off craigslist a 2002 hp dana 60 from an f350. been stored since 2003 in a garage. complete minus gears for $240

I need to find an appropriate rear end or Ill have to run a wheel stud conversion so I have the same wheels all around.

Ive started the narrowing on the 60 and it sits at 62" WMS-WMS. I want minimum 37's and Ideally 40's with lots of body trimming and not too much stick out past the fender flares.

here's some pics of the day I bought it, bumper build, 4 runner seats, axle narrowing and what ever else I can find in my computer, lol.

I would love lots of feedback and criticism on what im doing wrong or right so I don't build myself into a corner, so to speak. My building background as far as trucks goes is green, but I am a certified welder since 2007 with basically 4 years of fabrication experience in the R&D field of machinery. I know how to build it strong and I have some good common sense going on in my brain,

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these two are of the day I brought it home. those are 34's with roughly 70% left

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Used factory bolt holes with 3/4" by 4" flat bar for a tow point. winch plate is 1/2" plate. mounting bracket is laced through and welded both sides.

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re-used the bull bar that came with the truck. I like the look of it

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This is the rear bumper that came with it. I cut off the weak side extension and the tow points. The tow points were only welded to the face of the bumper and no where near inline with the frame.

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old one vs. mine. I laced mine through the bumper, welded both sides and welded it to the bumper bracket that gets bolted to the frame. much better.

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I also made some slots for some fogs lights that I re-purposed into reverse lights. wired in a relay and used the power wire for the stock reverse lights as the switching wire for the new relay. basically when I put it in reverse the relay closes and power goes down the newly run line to the new lights.

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got some leather and abused 4runner seats for $60. welded some 1/4' flat bar
highlighted with red arrows to the seat frame. then welded my stock seat frame to the flat bar.

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meaning everything bolts up stock and is strong and comfy as hell


On to the 60!

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old jewlery

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no jewlery

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this is how much im cutting off

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here it is re-welded

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I did a root and a two pass cap. due to not having a proper jig to hold it how I want, I had to cap it in 3 sections. though the welds are strong they are ugly to me. I have a few peaks and valleys going on that im not thrilled about, but not overly concerned with.

 

[Sasquatch_Ryda]

Looking good!

I've got a similarish build under way. Narrowed D60 and Sterling 10.25. Both are at 62" WMS to WMS on 40" LTB's

 

[wizkid00104]

Looking good!

I've got a similarish build under way. Narrowed D60 and Sterling 10.25. Both are at 62" WMS to WMS on 40" LTB's

Is that going to fit back out of the door you drove it in??? It looks very close...

 

[88_Eddie]

looks good

 

[Devorak]

Sasquatch_Ryda: Thanks, I was actually looking at your build thread trying to figure out how much to cut from my long side. what do they say? imitation is the highest form of flattery? lol.

 

[Sasquatch_Ryda]

We wouldn't post pictures of stuff we do If we didn't want people to use it for inspiration or direction!

 

[railman]

nice start

can't wait to see some more progress...

l8r, John

 

[racer1044]

Def watching this build I love this body style ranger. What is the specs on the truck in the first two pics?

 

[Devorak]

Def watching this build I love this body style ranger. What is the specs on the truck in the first two pics?

Specs of the first two pics are in my sig. Only thing I've added are belltech 6400 shackles

 

[4.0B2]

subscribed.

 

[racer1044]

Sorry man lol guess I didn't even notice they were in your sig. How do you like the tires? I have the same ones for my 89.

 

[Devorak]

Sorry man lol guess I didn't even notice they were in your sig. How do you like the tires? I have the same ones for my 89.

They are ok, I find they drone at hwy speeds and are a little rough rolling before they warm up. hard to balance, but then again they are meaty truck tires, not performance slicks, lol.

 

[Devorak]

did a little more today, I'm researching different truss designs before I start building my own. but for meow I cut 2 1/2" from the driver side pumpkin. no plug welds were cut and with a truss I will have a stronger axle. I did this to get more room for the truss and more space for the coil over.

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[Devorak]

UPDATE:

Started building a diff cover today out of 3/8 plate. got the ring done and bolted to the axle and then I started work on the truss. I dont want to weld to the pumpkin so I added a tab to the diff cover that will bolt to the truss in the middle. I know it's a little ugly right meow, but this is still the fab stage.

here is how the ring turned out. I only had to slightly oval 2 holes to get everything to line up

The truss tab will be cut down and gusseted. not that it really needs it.

The portion over the pumpkin is 3/8" thick. I think blue torch fab was my inspiration for design

the rest is out of 1/4" and I am going to make a front/ back plate to tie everything together. that plate will be one piece and will also cross over the pumpkin.

 

[Devorak]

taking a step back from putting 1 tons in. it will happen, just much later.

heres what Ive been up to these past few weeks.

finally got the engine in, did it by myself and it sucked, lol. here's the proof

also I tigged my p/s fitting to a gm saginaw fitting so I can use my ranger ps line for a saginaw swap

got the tranny bolted tight and the motor mounts and header y pipe has been rewelded. I had to cut it because the header nuts were rotten when I went to pull the engine originally. Ive also started reworking the exhaust. The resonator is welded in, its a 14" x 6" straight through can. the 8"x5"x18" single in dual out muffler is shoved in place while I cut and route piping. lots of room under there and easy to work since the bed is off. tomorrow it will be done I hope.

I also picked up 2 stainless hose barbs. 1 1/4" and cut the threads off and welded them together. drilled a hole and welded a stainless 3/8" npt fitting and made myself a thermo switch adapter that fits my rad hose

hardly hangs down at all, and the resonator is tucked right up there. Im thinking heat shields are in order though.