Completed Project Kirby's 1991 Ranger Build Up

[RockRanger]

I like the setup. Much lighter then the heavy pig of a skidplate setup I built.

 

[Kirby N.]

Thanks Matt! I am happy with the way it came together. Countersinking the bolts was a bit of a pain in the butt.

I got a lot done today. Both trac bar Mounts ended up tilted 15 degrees for clearance. I got the lower one burned in.

Welded to the c for extra brace. It was as far over as possible. For the longest track bar possible.

The trac bar and drag link will be with in an inch of length and a couple degrees.

I got the upper burned in too.

I got the coil bucket burned in too.

I am working on hacking the crossmember now. Will continue tomorrow but my rubicon has a screw in one tire, so I have to fix that first.

 

[Kirby N.]

I got my crossmember hacked out. I used a cutoff wheel on it. When cutting overhead It broke a wheel and caught and ripped out of my hands. It landed in my lap and cut my pants and underwear from my butt to my belly button. Barely got into my inner thigh. I an feeling lucky. It could have removed my manhood. Made me nude in a heartbeat.

Crossmember brace. It is 3/8" thick. Should be enough. I put some holes in it for speed. I may open up the existing holes behind it to the same size. That might make it work in the rocks better?

I just picked up my track bar, but I have to be done for the day. It is really close now. I have to measure for shocks and drill a bunch of 1/2" holes.

 

[BKennedy]

Good thing you were wearing pants. I have what I know us a horrible habit of wearing shorts and beach sandals when I am working on vehicles.

 

[RockRanger]

Good thing you were wearing pants. I have what I know us a horrible habit of wearing shorts and beach sandals when I am working on vehicles.

Must be a California thing. That is my favorite garage attire as well.

 

[5spdman]

I think that's just true man attire....I wear shorts as well and a cut off shirt when welding in Ohio....not just a CA thing!

 

[Kirby N.]

Whatever attire, be careful or be neutered!

 

[Kirby N.]

The worst part is I jumped up and ran out in front of my house to make sure everything was still there. After a quick inspection and a giant sigh of relief I realized I was not dressed appropriately for the front yard!

 

[5spdman]

The worst part is I jumped up and ran out in front of my house to make sure everything was still there. After a quick inspection and a giant sigh of relief I realized I was not dressed appropriately for the front yard!

I'm sure that was quite the sight for the neighbors lol!

 

[BKennedy]

The worst part is I jumped up and ran out in front of my house to make sure everything was still there. After a quick inspection and a giant sigh of relief I realized I was not dressed appropriately for the front yard!

Not only do your neighbors have to deal with the sounds of fabrication, now they have a whole new visual as well..

 

[yostyexplorer94]

I wheeled my explorer sport with 4.56s and 37s with no doubler for years so I know where you are coming from. I also built a doubler and installed it on that rig so I know the difference it makes. However, This is a multi purpose rig that won't live in the rocks everyday. It will haul my butt to work everyday and hual all sorts of stuff in the bed. It will also drag a trailer around and do the occasional trail. I think it will be fine. If not, I will start saving for an aftermarket tcase, not a doubler.

Yeah you're right, for the intended use it will be good.

I never had a cut off wheel completely let loose on me, but I worry about it everytime I am using one. I was happy to read that you didn't loose anything when I saw the pictures!

 

[Kirby N.]

I got a few things done. Everything is painted. The trac bar and coils are in. Unfortunately, the trac bar upper mount rubs the coils significantly. It cleared the spring cup, so I thought I was good. Nope. Idk what to do about this. It will be loud and annoying.

I got the brakes all plumbed. I ended up using a 94 f150 rear hose for the center. It was a wonderful length, however, I did have to cut off the long side end, replace with a 7/16" (slightly larger) end and reflate. Other than that everything bolted in. The upper is connected to the engine crossmember. I mounted the hose on each side to the radius arm with some rubber lines mounts I got at lowes.

 

[BKennedy]

I know this might be a lot of work, but can you move the track bar mount forward 1/2"? It might be the best solution.

 

[Kirby N.]

I know this might be a lot of work, but can you move the track bar mount forward 1/2"? It might be the best solution.

That would be a ton of work. The reason I have it so far back is that it makes contact with the tierod on full compression when the wheels are turned. Obviously, that would be more rare than how often it contacts the coil and it would have been smarter to leave more room and deal with the tierod clearance issues. None the less, it is too late for both! Hacking it off and moving it would be an enormous task. Even moving it up to the next hole and trimming the bottom would be a task because of the inner support for the bracket. I am torn. I may redrill a 1/2" hole higher in the bracket between the two larger holes, possibly even further in or i may notch the current hole and slide over my adapters and weld them in place. I haven't decided.

However, it did leave the garage today!

The clanking from the coil and the lack of shocks make it a chore to drive, but I hope to get it dialed in this week. I ordered a set of bilstiens. Same part # as the rear.

 

[BKennedy]

That looks great. I noticed the radius arms are angled slightly down which will give you a little more compression clearance. Mine sit nearly level.

 

[BKennedy]

That would be a ton of work. The reason I have it so far back is that it makes contact with the tierod on full compression when the wheels are turned. Obviously, that would be more rare than how often it contacts the coil and it would have been smarter to leave more room and deal with the tierod clearance issues. None the less, it is too late for both! Hacking it off and moving it would be an enormous task. Even moving it up to the next hole and trimming the bottom would be a task because of the inner support for the bracket. I am torn. I may redrill a 1/2" hole higher in the bracket between the two larger holes, possibly even further in or i may notch the current hole and slide over my adapters and weld them in place. I haven't decided.

Can you space the lower coil mounts outward enough so it clears?

Is that your house in the background of this picture? You must have a spectacular view.

 

[RockRanger]

Looks great. Can't wait to see pictures of it in the dirt.

 

[Kirby N.]

Can you space the lower coil mounts outward enough so it clears?

Is that your house in the background of this picture? You must have a spectacular view.

The view is nice. I have redone a bunch of the interior, but it has a ton left to go. If my truck was done I would be working on it!

Spacing the coils out would be pretty disappointing since I worked so hard to get the lowers in the correct spot so there wouldn't be any bowing. I think I have an idea. I am going to drill a new hole in the track bar mount, a little higher and inside just a touch. I will have to cut up the inside gusset some how. Maybe a hole saw?? Then I can trim the outer part of the mount and run it.

I pulled the track bar in as short as it would go today and now the coil clears. Seems to ride ok- but its a little squirrelly. Unfortunately, there is some death wobble.

I tightened everything down and really tried to figure out what the deal is. I think I narrowed it down to the upper drag link Tie Rod end. Brand new, but unfortunately it seems to have some play. I think I will see if I can locate a spicer one and get it on hand before I tear into it. Its pretty absurd.

 

[Kirby N.]

I spent $50 on a spicer tre from napa and installed it. Unfortunately it didn't fix it. I think it is the sector shaft on the remaned gear box from ford. I shelled out the extra cash for the ford one so I wouldn't have this problem. Atleast it has a warranty I guess.

 

[BKennedy]

Only view I have at my house is the neighbors house across the street.

Death wobble usually is from the steering, so you are on the right track. Check some obvious stuff, like wheel bearings, loose bolts, etc. I know I might forget those thinking I just put it together and its all tight.

I like the idea you have with the track bar mount. If it works, you could plug the old holes for strength, and then it might look like you planned it that way.