Chop, Cut, Rebuild: DB_1's Ranger...again | Page 6 | Ford Explorer Forums - Serious Explorations

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Chop, Cut, Rebuild: DB_1's Ranger...again

Ok kiddies, time for my bi-annual rebuild thread:p:
This time I won't be messing with the suspension...well, maybe the coilovers.
I may need new coils so I don't have so much uptravel but I'll deal with that much later.

Since i'm barely working progress will be slow since I'll need a few parts and whatnot to get my rig functional again. Main things I need to purchase are new leaf springs. They are totally shot and to have them rebuilt I can buy a new set of Toy springs which i'm gonna try out.

In the mean time, i've been removing stuff that either is damaged and won't be used again or just removing to get it out of the way while I work on stuff.

Here's my list so far:

Front bumper tubework: This will get reworked to accommodate the winch.
Front fenders: Thrashed beyond repair
Rocksliders: Been wanting to build new ones anyways so good as time as any to cut them off.
Rocker panels: Want to get the sliders up higher so they had to go.
Bed: Also trashed beyond repair, tubework will go in it's place
Gutted supercab area: Needed to remove for roof repair but may leave it that way and spray it with undercoating.

That's what i've done so far to the rig and I got my winch mounted today as well. I bought this winch early last summer before the roll and it's a SuperWinch Rock 9.5 short drum with synthetic rope.
I was pondering how i'd fit the grill back on since it sits behind it but i'd still need to access the freespool lever. My plan is to have it on hinges so I can flip it up, i'll just need a way to lock it in place at the bottom...maybe with Dzus fastners.

So on with the pics, i'll start with some before pics of the roof caved in and then with some of the roof almost where I want it. Still needs work obviously.
Other pics show the rockers cut and some general shots of the truck in its current condition. Last set of shots is of the winch install and grill mock up.

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I'm always available for a drop off point since, I'm only 20min from the main artery, between Nor Cal and So Cal;)

Happy to here your keeping the truck Dave, now get it up and running so we can plan a resurrection run to Big Bear ;)

Thanks...I think this is the last time I buy parts this way. Sight unseen except for pics then changing hands twice before it gets to me. I feel lucky to have it in my possession. I guess there is some humanity left in the world:)

The guy who hauled it down for me was dropping off his jeep at Stinkyfab to be worked on...from Oregon:eek: Then he went to PRP seats in Murrieta then was headed up to Tahoe area and back home. Life must be good when you can take time off to take care of your off road habit.
 



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Had the day off today so I went and bought some tubing. I'm back to work the rest of the week but hope to get started on sliders and tube bed this weekend.

Also tore into the D60 last weekend to pull the carrier and gears out. See if I can recoup a little money out of it. The carrier wouldn't budge by hand so I put a block of wood on the face of the diff housing then the hi-lift jack on that with a chain and a tow hook I had lying around. Put the hook in the carrier and viola! Pulled that sucker right out.
This axle will get a complete rebuild with new bearings, seals and associated hardware. The one thing i'm not looking forward to is removing the upper kingpins. They are on there with 500-600 ft. lbs. of torque:eek: I've seen some threads on various ways to remove them so I'll start with the easiest and go from there.
 












Not counting on it but i''m gonna try. I finished work early today so i'll see what I can accomplish.
 






Been working on the truck when I can but it's been slow going. Got the sliders done and welded in, got most of the tube work for the bed bent up except for the outer tubes which will be covering the wheels when all is said and done.

Here's some pics of whats done so far:
 

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One more pic to add...on the bed tubing, I played around with how I wanted to finish of the rear but nothing looked right. I tried bent tubing, didn't like it. Tried a 90 degree mitered joint but it was too straight up and down looking so I raked it back and I thought it looked good so that's what i went with. Had some spidey gussets to finish it off:D
Got work this week but with the time change I hope to some more done after work.
 

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Thanks guys, the plan is for the outer bed tubes to come off the vertical tubing behind the cab then covers the tires and will taper in at the end then connect to the inner bed tubes near the web gussets. From there i'll be filling in the blanks with support tubes where needed.
 






Finally got the main tube structure finished and all tacked up. Just need to get some more tube to make supports and either some sheet metal or aluminum sheet to make some skins for the bed and "fenders".
Spare tire will go up in the front area of the bed probably at an angle. Current shock placement will stay for the time being but I'd like to move them back outboard since I have more mounting options now.
I'd also like to make a tailgate which the license plate will mount to and maybe back up lights. I'll miter the corners of the tailgate to match inner bed sides.
 

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..Did you do the rainbows yourself??..:D

..Anxiously awaiting to see how you are doing the aluminum and bed work..
 






..Did you do the rainbows yourself??..:D

..Anxiously awaiting to see how you are doing the aluminum and bed work..

Like that:p:? My camera has a feature to add them or stars and a couple other things.

I'm anxious too, I have a general idea of what i want to do but just need to figure out how to do it. Basically I'll have an open area behind where the shocks are mounted now to throw a cooler, camping gear, etc.
 






..No fridge?

..I can't wait to se how this goes together to draw upon some ideas..Did you leave the rear springs/rear axle where they were on this rendition?
 






Yeah, fridge will go in the bed somewhere once I get a floor down.
Springs and everything are in there original locations. If you remember earlier in this thread I put in Tacoma leafs, new hangers and shackles. I had to modify the spring perches and spring plates to move the axle an inch back to get it to line up in the original location.
 






..Thats right..My mind was still on when you cut the bed and was trying to move the hangers forward..I forgot about the Tacoma springs..:confused:

..How soon do you think you will have the aluminum fab/installation work done?..:bounce:
 






I've got work next week so not much will get done. I need to make a run out to Patton's in San Bernardino to get more tube and sheet metal. I'd get it locally but their prices are ridiculous.
 






It's looking really good Dave:thumbsup: Love the look

My only question is are you going to add some support to the tube with the spidy gussets? The only reason I ask is if you back into a wall hard or something will it bend the tube that is actually part of the cage up by the cab? Hope that makes sense.
 






It's looking really good Dave:thumbsup: Love the look

My only question is are you going to add some support to the tube with the spidy gussets? The only reason I ask is if you back into a wall hard or something will it bend the tube that is actually part of the cage up by the cab? Hope that makes sense.

Thanks...yes there's a lot of support tubes that will be going in. These are just the main tubes made from 1.75". I'll be using 1.5" tube for all the supports.
 



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Can't wait to see it all done up Dave! Awesome design as always!
 






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