1999 Ranger SAS (Dana 44/Ford 9 Inch)

well here is what i started with:
put 32s on it and wheeled it too hard for the stock **** to take, needless to say, i broke a bunch of ****

when the decision was made to do the sas i picked up a 1979 bronco as a donor:

 

[bozone802]

i started off the project by taking the bronco apart and keeping what parts i needed and selling what i could.

i kept the axles and suspension stuff

 

[bozone802]

chop chop time!!!

 

[bozone802]

first order of business on the build was to plate the frame. as you can see i have good plates up front, but i now regret what i did in the back. i put plates on the inside of the frame in the rear when i should have just boxed it. so basically the plates on the inside of the frame were a good idea, but i should have boxed the frame around that for more strength.

 

[bozone802]

just a little fyi, the only welds i didnt do on this truck are the front frame plates, the rest i did myself after learning to weld when a friend gave me a 10min crash course. it is obvious where i started welding and what i welded recently because i am getting better everyday, and when i first started was on the rear frame plates so they basically look like ****! but its all good!

 

[bozone802]

after the frame plates were done it was time for some rear crossmembers. i put a huge hunk of steel in the rear (not sure exactly what cause i found it in the scrap pile) and used 1.5in .120 wall tube for the rest.

strap holding frame at the correct width:

2 crossmembers:

a few more of the rear:

i also put small plates on the outside of the frame where the mid crossmember is to give me a little more metal to weld to:

and when i was done it looked like this:

 

[Dezert_Dawg]

Might wanna move this to the offroad projects forum. This is for finished SAS projects

 

[bozone802]

it is finished, im just showing how i did it. havent got that far though seeing as uploading images takes forever and i dont really like sitting at my computer for that long... so ill get there soon dont worry

 

[bozone802]

next on the list i mounted my front axle. just used the stock spring buckets and shock mounts from the bronco and the springs are a 4" rough country lift springs, and i used the stock bronco track bar and steering
also up front is a FJ 60 steering box connected using 3/4 DD X 3/4 DD u-joint off the firewall into a DD shaft, then into a 3/4 DD X 11/16-36 spline to fit onto the steering box.
there is also a new power steering pump with new custom lines to fit onto the FJ box.

 

[bozone802]

Rear end:
used 4 front leaf spring hangers to mount the leafs, then got a new yoke and u-joint to hook up my stock driveshaft and set the pinion angle, then mounted the shocks, mounted removable mud flaps, then i put the bed on, chopped it a bit and put on some cheap spray on bedliner, then i mounted a temporary bumper and had a hole torched in it for a hitch cause what good is a truck that cant tow? and lastly i mounted my licence plate with bolts with leds in them to light up the plate

 

[bozone802]

i also did random things like put in a 10 inch sub and mount the cb antenna on the toolbox

 

[bozone802]

now my truck is sittn pretty, well actually it has a bit of a drivers side lean, but whatever, no worries ill tweak that sometime in the near future. and it pretty much looks like a billboard but it already looks ridiculous, why not make it a little more!

 

[94 Crawler]

Hey man your truck looks great how dose that bronco box work for ya. I need to try one on my wifes Montero but I've been to buisy with my Volksrod project to even think abought a 4wd.

 

[TarHeel085]

It does look good! where did you get the steering shaft made?

 

[Ranger99OR]

Hey there,

I have been a fan of this build for a while. I have been wanting to do an sas for a while, and have recently decided to start planning, I have a few questions.

First, did you have to change your spring perches on your axles?

And are the spring mounts(on the frame) fabbed up or the stock ones?

I am just debating if I need to make new hangers for the front and rear or not.

Thanks.

 

[yostyexplorer94]

i love it what welder did you use?

 

[+RABBIT+]

looks like mig

 

[Ranger99OR]

Ranger SAS Help

I love this truck and how he did everything. I dont know if I will get a response from him but does anyone know if he had to make and reset his mounts on his 9 inch axle for the springs. I am wondering if using those hangers gives him the right width or not.

 

[bozone802]

I love this truck and how he did everything. I dont know if I will get a response from him but does anyone know if he had to make and reset his mounts on his 9 inch axle for the springs. I am wondering if using those hangers gives him the right width or not.

wow that was a long time ago i pretty much forgot about this. i had to cut the old perches off the 9 inch then weld new ones on.

thanks for liking it! I like it too, and its not bad for being a learning experience for me. now there are lots of things i would have done differently. i learned how to weld on this truck and amazingly non of my first welds have broken (they are still there).