RDC Project Vehicle - Ford Ranger

[klaus]

<div align="center"> <center> <table border="0" cellspacing="1" style="border-collapse: collapse" bordercolor="#111111" width="100%"> <tr> <td width="50%" align="center"> <img border="0" src="http://race-dezert.com/forum/attachments/project/klaus/klaus_ranger.jpg" width="275" height="50"></td> <td width="50%" align="left" valign="top"> <p style="margin-top: 0; margin-bottom: 0"><font size="4">1990's Ford Ranger Prerunner</font></p> <p style="margin-top: 0; margin-bottom: 0">&nbsp;</p> <p style="margin-top: 0; margin-bottom: 0">I-beam front suspension - 3 link rear suspension - V8 powered - coilover and by-pass shocks - 2 seater - SCORE legal race-gage&nbsp; </p> <p style="margin-top: 0; margin-bottom: 0">&nbsp;</p> <p style="margin-top: 0; margin-bottom: 0"><b>Sponsors:</b></p> <p style="margin-top: 0; margin-bottom: 0"> <a target="_blank" href="http://wizardfabrications.com/">Fabrication = Wizard Fabrication School</a></p> <p style="margin-top: 0; margin-bottom: 0"> <a target="_blank" href="http://www.foxracingshox.com/">Shocks&nbsp; = FOX SHOX</a></p> <p style="margin-top: 0; margin-bottom: 0"> <a target="_blank" href="http://www.visioninet.com/">Lights = VISION-X&nbsp; H.I.D lights</a></p> <p style="margin-top: 0; margin-bottom: 0"> <a target="_blank" href="http://www.bfgoodrichtires.com">Tires = BFGoodrich</a></p> <p style="margin-top: 0; margin-bottom: 0">&nbsp;</td> </tr> <tr> <td width="50%">&nbsp;</td> <td width="50%">&nbsp;</td> </tr> <tr> <td width="100%" colspan="2">The Objective of this vehicle is to have a playtruck for the desert capable to prerun race courses such as the SCORE Baja 500 and Baja 1000 at a high rate of speed with a minimum of breakdowns. On raceday this truck will function as a vehicle to get from point-a to point-b in a hurry in order to get to photography spots alongside the racecourse. The truck will be raced once or twice every 2-3 years in sportsman in selected races once it has proven to be reliable. Inspiration comes from <a href="http://pix.race-dezert.com/albums/2005_score_sf_250_cont/normal_IMG_6297.JPG"> The Penhall Ranger Prerunner</a>, &quot;Drywall Gary's&quot; Prerunner among some others to be posted in the subsections. The primary fabrication will be done by Klaus as a student in Wizard Fabrication school. in Riverside CA. All aspects of this projects will be documented in this section.</td> </tr> <tr> <td width="50%">&nbsp;</td> <td width="50%">&nbsp;</td> </tr> <tr> <td width="100%" align="right" colspan="2"> <div align="center"> <center> <table border="0" style="border-collapse: collapse" bordercolor="#111111" width="80%" cellspacing="1"> <tr> <td colspan="2"> <p align="center"><b>Project Subsections:</b></td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> <tr> <td colspan="2">1. Planing, Inspirations, Mission Objectives, Project Layout.</td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> <tr> <td>&nbsp;</td> <td>&nbsp;</td> </tr> </table> </center> </div> </td> </tr> <tr> <td width="50%">&nbsp;</td> <td width="50%">&nbsp;</td> </tr> </table> </center> </div>

[klaus]

The project will gets a hands on start February 1st at the Wizard School of Fabrication. I am pretty nervous.

[KELLENC]

Klaus. do you have any specific design ideas? if not this is the best place to get them! Is going to be the official RDC truck?

[klaus]

Well yeah i have tons of ideas. they are not all firm and i am open to feedback.

I am no egomaniac so I have no problem crediting the fabricator out there who's ideas influence me (read copy). There are a couple of fast Rangers out there and I have been looking them over for a while.

My first subsection will be a long wish and idea list.

[ShaneR]

Klaus, will the ranger project be 4X4 or 4X2? If 4X2 why not a-arm?

[KELLENC]

Well yeah i have tons of ideas. they are not all firm and i am open to feedback.

I am no egomaniac so I have no problem crediting the fabricator out there who's ideas influence me (read copy). There are a couple of fast Rangers out there and I have been looking them over for a while.

My first subsection will be a long wish and idea list.


Great. I look forward to seeing the build up from the ground up.:)

[Gabe_Lara]

Good job, Klaus!
Glad to see you're gonna get this project rolling.

-Gabe

[klaus]

ohh yeah gabe, your Ranger is also an inspiration. Please post some pictures of Mini-Jet-Blue please.

[Sic_Racing]

sweeet klaus...question...is the ranger gonna be a full all out prerunner..or will you make it somewhat street legal? you know..a bit more practical...

[klaus]

It will be street legal and driven on the street. no trailer. Not daily driven. Stealth to not get pulled over all the time but Offroad enough to prerun an entire Baja course. Once I am comfortable driving it I will race it once every 2-3 years in sportsman just for the fun of it.

Mainly I want to use it to get around on raceday. Currently I don't even own any truck or offroad vehicle and end up renting small 4wd SUV's for the Baja races.

I am collecting ideas right now. I went to Camburg today and looked at a new extra-cub Ranger being caged, Jeremy's A-Arm Ranger and also the EDGE that Camburg raced in Baja. I need to take a camera on my next trips to collect and share all the design hi-lights I can find and share it here. Jason Campbel of Camburg gave me some good pointers for the project as well.

[Bryan_D]

Its about time that you get a truck for the races.

[steveG]

Klaus I've wondered if you'd ever build a truck. Sounds like it'll be a lot of fun. Have you done any fabrication work in the past?

[klaus]

That's the nervous part for me...My only hands-on background comes from two Blazers I had in the past. My friend and rdc co-founder Paul and myself build a shock hoop in the front and rear to hold 2 sets of 2.0 fox shocks at each corner plus we mounted National leave springs all the way around. That by itself made the truck run much better then stock. Then we concentrated on the engine and ended up with a 400hp 408ci. That made it fast and unsafe. Next we mounted beard bucket seats and a 5 point seatbelt. The driver side seat utilized a stock style seat slider.

Then the plan was to convert it to a stock style a-arm setup with extended a-arms. Jason at Camburg performed that job for a customer at the time but I did a reality check and came to the conclusion that a Blazer wasn't the right vehicle for what I wanted to do, I had no money (not that I do now...) and a couple of other things. The motor was out at the time as well so I ended up selling the truck.

So my fab background is based on all around automotive work. Two shock hoops. seat mount. A center console. I have seen it done over the years and I feel with the help of the Wizard School it should get done. I constantly talk to a couple of friends that do this for a living and they are willing to lend a hand alongside the progress.

[Curtis Guise]

sorry Klaus couldn't resist.... remember this race?

[klaus]

yes I do....wow that was a long time ago. pre-rdc days.

what happend was we preran a mdr race the night before the race (smart) and the spindle let go on the passanger side. We got some help to get it back to the pits. Then on raceday I did my pit and chase duty for a team. Then after the race I asked for a ride to the local greyhound station. Greyhounded back to LA. Took the girls car (Saab 900) and loaded a complete hub to hub spare axle into it. Drove to Barstow and then in the afternoon after raceday exchanged it alone. Drove home.

Yeah my Blazer days are counted and over. I'll just run shotgun in John Project when it done.

[Curtis Guise]

I think I raced that race and my co-driver Ryan went to drag the Blazer back from the sand wash at around 2am. Good times....

[steveG]

...exchanged it alone. Drove home.

Wow Klaus, that's good stuff!

[Doug]

Right on Klaus, glad to see you excited, even if you are nervous a little bit. Once you get going it's no big deal. It's just a matter of doing it. I'm sure you will be a natural, most serious off-roaders pick up on this stuff very quickly.

[matt_helton]

sorry Klaus couldn't resist.... remember this race?


i remember following the 10" ditch from over near /x all the way back to main! and there was the blazer. lol

[sirhk100]

Wait wait wait, stupid question but how'd you get both vehicles home if you did the swap solo? Did you leave the saab out there?

[matt_helton]

yeah, he just burried it there. its the best ending for any saab. lol

[klaus]

g/f drove her Saab home. She was thrilled to have a fullsize front axle sticking out of it while crawling up the cajon pass.

[steveG]

g/f drove her Saab home. She was thrilled to have a fullsize front axle sticking out of it while crawling up the cajon pass.

LOL. It's a shame there's no pic. That's classic!

[matt_helton]

yeah, almost as good as that pic of the looters that had the 65" tv hanging out the back of their ford festiva.:)

[klaus]

Update:

Purchased core vehicle today. 1994 Mazda B4000 4wd, 4.0, Auto, x-tra cab.

A Mazda B2000 and B4000 truck is the same as a Ranger. The differences are the trim around the side windows and doors, the grill and badges.

In 1993 Rangers changed the cab design slightly. There is no rain gutter like the pre-93's have.

4wd Rangers have a more desirable cross-member when going to equal link king-pin style beams.

It's a low budget truck I found in the classifieds.

It misfires(?) a little, has a check engine light but I am sure its something I can fix by doing some tune work. I want the engine running fine even though it will ultimately be replaced by something v8-ish. Smog is due and I took on the responsibility of making it DMV complaint. A well running 4.0 engine has more resell value then a questionable engine on a crate. There are a couple of other minor issues but nothing of major concerns. The good thing is that I now have lots of the small parts that a cab and frame wouldn't offer.

I will post a more detailed cost analysis that will show initial investment minus parts that can be sold. Hopefully it will turn out to be close to free-ish after selling components of the core vehicle.

I will enroll into the Wizard School late February. That means I will have a truck to drive until then or actualy slightly after.

[John_Bitting]

Kleezay FINALLY has a truck he can take off road. Congrats, cant wait to see what you do with that thing. You better make it fast my blazer is gonna be tough to keep up with..:-)

[klaus]

Thats it... $100.00 bet I smoke your blazer at a future MDR or CODE race.

[ChuckH]

Uh oh, the gauntlet has been thrown down

i have thought about making a post about a RDC build shootout when you 3 are done.

Seems it wasnt needed.

[Curtis Guise]

I already have a year of testing on mine... ;)

[klaus]

ohh Curtis you want some too ? its on.

[wizfab]

Wow Klaus. Looks like you better come in early to class and get an edge on these guy's. Don't be nervous, it's easy to learn so you and the others can build one bad *** truck. Come by the new school and check out how big this place is. I will be there all weekend with the crew finishing up for class on Monday if anybody wants a tour. Later.
The Wizard............:)

[AaronB]

Hey Klaus, any specific reason you're not going to keep the 4x4?

[steveG]

I wondered the same thing.

[John_Bitting]

Yeah, tell him all the benefits and how nice it is in Mexico. (his second home). Plus he can pull me out if need be.

[steveG]

Up to 21" of wheel travel AND 4wd. How many more benefits do you need?

[Tom_Willis]

[QUOTE=steveG]Up to 21" of wheel travel AND 4wd. QUOTE]

Who has a 4wd setup for a ranger with 21" of travel?

[steveG]

Autofab's D44 TTB conversion for Rangers/Explorers is capable of 21" of travel with properly mounted coil-overs.

[klaus]

project will be a 2wd and i have some resoning behind it. will post my thoughts on that soon, but basicaly it comes down to weight and cash. I had a 4wd before and never used it. This vehicle is ment to go fast and not get stuck. 2 seater, not a family ride. Not a chase vehicle that has to pull vehicle out of holes (not that i wont help you out, just not by design).

[klaus]

Update:
Picked the vehicle up from Ventura today where the previous owner resides. Next step will be to get it registered and smoged. I agreed to take care of that vs. the seller. It runs poor and needs attention. So I have my work cut out for next week.

[partybarge_pilot]

ohh Curtis you want some too ? its on.


After seeing Klaus's mad off-road driving skills in the Moostang, My moneys on him.....

[partybarge_pilot]

Autofab's D44 TTB conversion for Rangers/Explorers is capable of 21" of travel with properly mounted coil-overs.


Yeah, about that...... The uni-ball on the beam will only alow about 18" with the spacers they give you. If you want more your going to have to do a little machining.

[steveG]

Sorry to take your thread off-track Klaus. After this I won't post another word about 4wd in your thread.


Yeah, about that...... The uni-ball on the beam will only alow about 18" with the spacers they give you. If you want more your going to have to do a little machining.

Like I said, it's capable of 21" of wheel travel. The truck they are installing the first kit on is going to have around 17" of travel.

[klaus]

Update:

Just confirmed my seat at the Wizard School of Fabriaction for the February 23rd class.
Starting then we will have weekly updates on the school program ( rdc secion > Shop > Wizard ). The core ranger/mazda wont be cut until about 1-2 month into the school program. In the meantime I will start parting out the vehicle and offer parts for sale to offset the initial buy-in costs. The entire costs will be listed here to get an idea of what it takes in the wallet department to build a vehicle.

[Sic_Racing]

Nice :D thanx for the update klaus!

[RRose]

I can't wait to see what you are going to put together Klaus!

[sirhk100]

Uh oh, first day of class is coming tomorrow!!! Did you get mom to buy new school clothes? Make sure you get a new lunch box!!! I heard Gem is out and Scooby is coming back!!!

Can't wait to see what you guys do with this truck!!! It'll also be a cool way to see what the wizard skool is pumping out.

Khris

[klaus]

yeah I am all nervous...back to school

[wizfab]

Don't worry Klaus, Danny Porter will have you fabricating in no time. Also come to class hungry, will have pizza and sodas for tonight, as it's just an orientation class. So you don't need the school lunch box tonight.(south park)

[sirhk100]

I know it's early but how's class going? Seem like something that's going to work out cool? Forget your lunch yet?

[picone]

Is the ranger done yet?

[Tom_Willis]

Like I said, it's capable of 21" of wheel travel. The truck they are installing the first kit on is going to have around 17" of travel.[/QUOTE]

But does the front end look like \ / at full droop?

[steveG]

PM sent twillis.

[TheWebWheeler]

Ok so whats the latest ....
I wanna follow this one....http://www.thewebwheeler.com/forums/images/smilies/popc1.gif

[klaus]

Hands-on has not started yet.

I am collecting ideas and really need to take photos and share them here on the forum of what I have seen out there and like. The in-cab-rollcauge will be a late Camburg design with some of my own ideas in it. Aren (sp?) who works there is working on his Ranger and I like what I see.

Keeping is SCORE legal is another issue. Tube thickness and design will be in complaince even though I don't see myself racing the vehicle in SCORE any time soon, but who knows.

I have a Camburg rear 3 link suspension system, four 35" Baja BFG tires, 2 out of 6 Vision Offroad HID lights sitting here next to the core vehicle. Mastercraft will supply the seats when it comes time. Fox will be the shock of choice. Howe will be involved with the steering and I am talking with Doug at Desert Specialties about rear-end and hub options. If budget permits a LS2 is the motor of choice due to its power vs. reliability ratio.

Next stop is to smog the truck, finish my DMV registration, next move it to the Wizard Fabrication School for disassemble and then the fabrication aspect will start in 1 to 1.5 month.

[Jefe_Negro]

:cool: Man...

Right on Klaus... good Chit, can't wait for some update shots!


Oralé Bato!

[TheWebWheeler]

I've gotta ask you Dude!( Klaus )
Do you feel alot of pressure, that you've gotta build a "BAD ***" rig considering your are KLAUS the guy behind the NO# 1 Dez site on the net.....??? I just had to ask. http://www.thewebwheeler.com/forums/images/smilies/shrug.gif

[klaus]

The Truck is now at the school and will start disassembly today.

[klaus]

Teardown of the truck has started.
All parts will get striped of the vehicle until it is just a cab and frame.
While taking things down parts will get separate between, keep for reassembly, keep for sale or trash.

[Bryan_D]

Was that a Mazda?

[baja619]

Lookin good let us know when you need some skins, dash and a clip for that thing

[klaus]

FiberwerX all the way....

[klaus]

Here are photos from one week ago.
Currently the truck is 99% stripped and sits on the table....

[klaus]

At this point the truck is nothing but cab and frame.
Getting the windshield out was a big messy pain.

We also washed down the grease from the frame at a local carwash.
In the 3rd picture you can see Chris the School Manager give me a hand (for the photo) on the pressure washer.

Teardown phase is now completed.

[klaus]

As part of the Wizard Fabrication Class we built jig tables on wheels. This way every class project can be moved around the classroom and wont take up space while another class is in session plus it gives a level platform for the project.

The table can be set level with set screws in every corner.

Our table is square within 1/16" diagonal.

After the table was built it took only one night to move the Ranger Cab on the table and tag-weld it into place.

We found the center of the Vehicle and lined it up with the tables center. Since the
cab and frame are built rather loose we had to opt for the best average between cab and frame. We picked a couple of points in front and in the rear of our vehicle to go by.

This phase is now completed.

[aiiraciing]

Klaus, will you be boxing in the Frame

Brian

[Jarvis]

Nice to see things comming along. Keep updating we wait with baited breath.

[jeff]

Updates... we want UPDATES!!!

Aloha

PS - Pictures too please.

[klaus]

One of our project sponsors Camburg Engineering provided me with a 3-link kit as part of the rear suspension.

The kit consists of a pair of lower control arms, upper wishbone link, all mounting brackets and mounting hardware and heim-joints. All that is missing is the mounting brackets connecting the rearend. The guys in the shop gave me a paper template to cut out and weld the lower link brackets to the rearend housing.

Installation required the removal of the stock carrier-bearing mount as it gets replaced with a tubular version supplied in the kit.

The mounts utilize the stock holes in the frame. Large rivets need to be removed and replaced with supplied bolts. Additional holes need to be drilled, but the location is obvious once one starts to install the kit.

Removing the stock rivets took the longest.

Using a kit vs. designing and building my own links saved a tremendous amount of time. I also know that this kit had undergone some revision changes from its initial design and by using a tested design it eliminates the trial and error on my part.



http://camburg.com/images/Ranger/3link/kit2.jpg

[klaus]

more pictures

[klaus]

We cut the rear frame of after the frame as the truck will be linked and get a tubular frame in the rear.

[klaus]

Fox Shox supplied the project with some mark-up shocks.
A 14inch 2.5" coilover and one 16inch 3" 4x bypass sock.

Fox Shox will be used for all shock needs around.

[klaus]

Before the project actually started I was under the impression that building the rollcage is simply one phase by itself independed from all other components of the truck. Quick did I learn that all aspecs of the vehicle tie into each other. The tubing behind the cab connects into the cab at multiple points and close attention must be taken right away on the cab cage design.

Since the new SCORE rules ask for 2" tubing for all trucks over 4000lbs the project Ranger uses 2" 4130 tubing for all its main roll-cage structure. It may seen overbuild but thats what the rules call for and even though I plan not to race the truck anytime soon it would be a disapointment down the road if I would want to enter it in a SCORE event but couldn't pass tech.

All welding is done by MIG rather then TIG in order to save time and for simplicity reasons.

[klaus]

Picture of the first 3 tubes of the cage.
This will connect close to the rear shock mounts behind the cab.

The horizontal tube is set some further back then the b-pilar of the vehicle allowing for more legroom and relaxed seat position. This horizontal bar will be the mount for the shoulder portion of the 5-point seatbelts

[klaus]

Next the horizontal bar gets tied into the frame below.
We cut out large holes above the stock framrails.
These holes will be patched up with sheetmetal down the road.

[klaus]

Here a main-tube connects from the front of the cab outside frame to the rear roof.
We used three tubes per side, each one with one bend (total of three bends). Using three sections was a lot easier then making it out of one single tube. However all pieces are "roset-welded", got tagged inside the cab, then the total assembly got removed and welded permanently outside on a bench. That way we were able to weld around the entire tube and not skip those hard to get to places that are often overlooked.

Some of these tubes will be in plain view close to the windshield, so we sanded down the excesive welds to give the joints a flawless look. It doesn't fully look that way right now, but once the cage is painted it will be (hopefully) invisible.

[klaus]

pictures show more progress.

[klaus]

Pictures of the tubes connecting left to the right side.

[klaus]

The rear frame section of the vehicle will be tubular. We removed the stock frame rails behind the cab. Going this route has a couple of advantages as we are no longer limited in up travel by the factory frame. We will also be able to widen our frame and suit the needs of a prerunner more rather then working around a OEM design by Ford.

We started by simulating the full compression of the rear suspension. Marking the area the rear-axle will be under full compression. The rear-end will be a Desert Specialties (http://www.desertspecialties.com/) "Full floater" that is on order. We also "quick" mounted the Fiberwerx (http://www.fiberwerx.com) fenders that will be used. Then we marked the area our fuel-cell/fuel-tank will be located. Since its fully custom we can design for a large capacity tank at this point. The tank will be in the very rear of the vehicle and needs to clear the ground under full vehicle droop.

The last 2 classes where spend with lots of marking up and simulating components, drawing and pocket calculator in hand. I feel that planning is key to avoid lots of aggravations down the road.

[klaus]

Some pictures of new FiberwerX Rear fender.
Its a a shortbed, 6inch model.

It will be mounted bowing out a bit rather then straight and parallel with the stock bed dimensions.

[klaus]

Every vehicle from OEM to Formula One is a knock-off someone elses ideas. The only original car was the first one build by Daimler a little over 100 years (http://www.ausbcomp.com/%7Ebbott/cars/carhist.htm) ago and even he copied aspects of it from other inventions.

I am making no secret out of it that this project is a blatant copy of vehicles out there. Instead of claiming I came up with this and that I will share photos that I have collected to guide in the design. Credit where credit is due.

Some of these pictures I found on other website and I'll try to reveal the source. Some pictures are from our classifieds others I shot on purpose for this project.

I will share some photos I have of vehicles that I feel are not what I want to follow but they have one little aspect I like.

[klaus]

The biggest influences are 4 Rangers that frequent our circles.

Gabe Lara's blue Ranger, Garry "Drywall" white Ranger, Carl Renezeder Prerunner and the ex-Penhall grey Ranger


This is the former Penhall Ranger.

www.desertrides.com had a nice feature photoshoot on it in March of 2004
http://www.desertrides.com/features/vehicles/penhall_ranger/index.php

.

[klaus]

more photos of same vehicle

[klaus]

more photos of same vehicle.

[klaus]

more photos of same vehicle..

[DEZERTBOUND]

Hi Klaus
I really enjoy watching your project come together. My brother is part of a team (DESERTDIRTDOGS) building a Mazda truck. They wanted your opinion, along with anybody else with one. Should they build a Class 7300/7sx or 7s truck.

p.s. is your trucks grill going to be a Ford or Mazda

[klaus]

The class rules for the minimetal trucks are all over the place and seem to change all the time. All the organizations have differemt takes on it, so picking a class will not be easy. I stay clear of that question and leave it to those that actualy race in those classes. My truck will also not comply in any class and will be a prerunner witha score legal rollcage so it could run in sportsman one day for fun.

The grill will most likely be a Ranger. I like the 2004(?) look and the grill has some advantages to hide some HID lights inside of it. Its not set into stone, but thats the plan. I also kind of like the Explorer conversions.

When is your truck due to be done?

[klaus]

Klaus, will you be boxing in the Frame

Brian

Yes I think so. It wouldn't be too hard to draw templates and then optic-eye plasma cut them out. Initialy I thought about doing that right away, but there are too many things that mount to the inside frame, so it will be done down the road.

[baja619]

I beleive the 04 and the 05 ranger grills are the or have the same options.

[baja619]

I agree that it looks better than the 2006 grill which is more similar to a Super duty

[klaus]

This is Gabe Lara's Ranger. The truck uses Newlines front and rear suspension and is powered by a mild 302 EFI V8. I like how the truck looks clean and innocent, yet has a good suspension letting it go fast in the whoops.

[klaus]

more pictures of Gabe's truck

[klaus]

more pictures of Gabe's truck.

The last photo is not the same truck but the same front suspension kit.

[klaus]

Center console with stock manual transmission.

[klaus]

Gary's Ranger

[klaus]

Shifting Project Purpose.

As some of you may know I am originaly from Germany and my family is still over there with no intention to ever move to California. Growing up my dad took me to some rally races and we constantly followed F1 racig on TV. Then once per year the Dakar came on and we listened for updates late night on the radio during the sport-news. This is all pre-internet and pre-sat TV. My dad has never been to this part of the globe and only knows about desert racing from DVD's I keep mailing him and he is hooked on watching over and over.

Well my new mission for the prerunner project is to invite my Dad over here once its completed to prerun a SCORE Baja race extensevly with me. Even let him take the wheel for a while and provide the most upclose desert racing experiece imaginable. The stuff I take for granted sometimes by now but a newbe would be blown away from.

[DEZERTBOUND]

My Great Grandma on my dad's side had so much of a German accent there was no hope of understanding her....but her Swede husband was a "lead" foot.that I could understand:eek:

[klaus]

more pictures

[DEZERTBOUND]

Hi Klaus, you asked when the "DESERT DIRT DOGS RACING" truck would be done?
I heard early to mid 2007. The days are long (and hot) so they are going full steam. These shots show them making room for seats, the belts this weekend and the Fox shocks very soon.

[klaus]

Today I took delivery of the Desert Speciaties (http://www.desertspecialties.com/) rearend. Its a full floater 3.5inch 4130 housing TIG welded unit. Axles will be 40-spline. The 3rd member will be a typical Ford 9-inch style.

Next step is to fabricate the 3-link mounts.

[jeff]

Sexy. I like the personalized "Klaus" logo in blue.

Aloha

[aiiraciing]

Klaus, its been almost a months since the last post, I was wondering if you had gotten any further with this Project?

Brian

[klaus]

more pictures.

- upper shock mounts are cut out of card-board for mark-up

[klaus]

more pictures. ..

- card-board templates got used to plasma cut shock mounts out of steel.

[klaus]

more pictures. . .

- with the shocks mounted and the trailing arm in place we where able to meassure our wheeltravel of 25inches.
- fuel-cell/tank frame

[klaus]

more pictures.. .

- shocks and mount are "semi low profile" behind the rear fender

[klaus]

ok just updated more about the rear build and also the beginning of the front.
I hope it meets all the "internet fabricators" approval....lol

Seriously I appreciate ALL feedback, good or bad.

[klaus]

In the front we will be using a Newline I-Beam kit with Desert Specialties King-pin spindles. For shocks it will be FOX Shox coil-over and by-pass.

[klaus]

- We started with mounting these bolt-on ibeam brackets. Installation was easy. All that had to be done was allign the first one based on some meassurments supplied by Nestor of Newline and drill holes in the frame for the fasteners supplied in the kit.

[Bryan_D]

Klaus the truck looks great man, do you have an estimated completion date for this? Oh and whats going to be the drivetrain? Stock 4.0 or built?

[klaus]

No date on the completion at all. As for drivetrain I am eyeballing a LS1/LS2 style engine and on trans I have some ideas, but its not solid enough to talk about.

Wish there would be a Diesel solution that has Ls2 characteristics....

[partybarge_pilot]

Wish there would be a Diesel solution that has Ls2 characteristics....


Don't we all.

[klaus]

One engine I like that might suit the needs would be the Mercedes OM 629 engine (310 hp and 538 lb - ft 4.0 liter BiTurbo V8).

http://www.jesmb.de/engine/pic/400CDI.jpg

I just read about another upcoming new super powerfull and compact Mercedez engine but cant find it online right now.

[kats]

Its taking some time but is worth it, it looks very good, when are you expecting to finish?

[partybarge_pilot]

How about the V10 VW diesel?

[scary fast hummer]

How about the V10 VW diesel?

If had the money and could stick it on an Allison 6 speed autobox, I'd put this engine in my H1 racer. The power out of these is crazy and get great milage. You ought to see the Tuareg VW's with these things pass you like a fence post!

[klaus]

mas pictures.. .

[klaus]

Jeremy (also founder of dezertranges.com) at Camburg welded the 3-link mounts to the rearend over at Camburg to the rearend.

[klaus]

more pictures..

[ryan_towry]

Isn't a mercedes or vw engine getting kind of exotic? you still have to think about repairs on the course and i don't think you are going to find too many parts for those anywhere around baja. and also what kind of price does one of those bring vs a ls2 is it really cost affective?

"i could be talking out of my a*#, but they say stick with what you do best"

[klaus]

yeah...it will most likely be a reliable and common LS1/LS2, I just like the mileage of a modern diesel.

I just got a chance to drive a diesel 1.9l 101hp VW golf for 3000miles+ in various forms of traffic and diesel is not what everyones perception is. Very far from it. Its very fast, quite, powerfull and 50mpg+.

Unfortunaly due to laws that don't seem to make sense not available in CA.

[baja619]

"Unfortunaly due to laws that don't seem to make sense not available in CA."

If you read into the statement it makes perfect sense why they would be unavailable CALI.

My perception not too many rules and regulation in this place seem logicial

[fab101]

Hey Klaus, I have some updated pics for you on your truck, Ben has been working on it. Its looking bad *****. Let me know what you think. -Chris

[spanski09]

klaus, what exactly did you learn in that wizards class besides welding and using the shop tools?

[AZBadseed]

I could be wrong but I think Ford offers a 4.(something)L v6 turbo diesel in those cab-over, box van type trucks. Could be something to check out. I'll see if I can find some more info on them.

[fab101]

The Wizard students learn a lot in our school. The first part of the class is set up for Mig and Tig welding instruction from our welding instructor. Next is tube bending and tube notching on various machines. We also teach our students chassis structure and frame design, along with the A-arm geometry and 4 link/3 link suspension geometry. This class is a hands on school and the students are the ones creating these vehicles with the help of the instructors. Hope this helps until Klaus gets to adding anything. Here are some updated pics of his truck.

[pjc]

klaus, what exactly did you learn in that wizards class besides welding and using the shop tools?


I'll answer that --- Many techniques that work.

I have dived in on complex notching, coping and bending. At times I will struggle and then John will show me a technique that is simple and correct that saves considerable time and provides the right strength and integrity. As an "engineer type" by profession, way too often I only look back and think "damn, I should have known that" but I didn't.

The only thing the class does not offer is a duplication of the time I spend there so I could have more time to work on stuff at home. Of course, that will come soon enough as we near the end of the course.

[klaus]

A small detail I picked up on a recent Port built Trophy Truck. I have seen this before but now I finally took a picture of it.

an open tube intersects with another tube without a midar-cut(sp?) fitting. Instead of leaving the end open it gets covered by a plate that wraps around all tubes involved. The Ranger project has 4 of those intersections at the very rear behind the fuel-cell. We will terminate it in a similar fashion.

[klaus]

Here we cycle the suspension side to side "duck walk".
Its an extreme and unrealistic scenario that left to right would go from full droop to full bump. A swaybar would prevent this plus the compressing side tire would lean so far inward that it would hit things it shouldn't.

The test was done just for fun and to see how much the trailing-arms and shocks move sideways. One tube gets close to the by-pass shock and we where looking for clearances.

[klaus]

Here are some more updated pictures.
The "b-pillar" roll-bar is now one piece under the roof.

[klaus]

more updated pictures.

1. Shows a more completed rear cage section.
2. Side view with temp mounted Fiberwerx Fiberglass Fender.
3. View from other side with two 33 inch spare tires.
4. Rear view with two 33 inch tires.

The truck will run on 35inch tires but that day we had no 35s available to visualize things so we settled for the smaller 33s.

[klaus]

Here we placed a 37 inch tire where a 35 will be once completed. This is the front spare. It will be hidden and harder to get to but this vehicle is a prerunner not a race-car. The compromise is a slower tire change for the 2nd flat. The advantage is a more compact design that will make room for a storage tray above the front spare tire.

Since no 35 inch mark-up tire was available we used a slightly larger 37. This worked out well because now the spare tire mount will be large enough to fit a larger tire if ever needed.

[klaus]

The vehicle will be powered by a Chevrolet LS1 or LS2 engine as its a modern EFI V8 packaged small. A V8 Overhead cam engine would be my choice for a modern power-plant but larger heads in a compact truck would require a more dense build. I know of a 32valve Ford 4.6 engine in a Ranger, but was not up for the challenge.

At the Wizard School of Fabrication in Riverside we have markup LS1 engines the students can use. First we build engine mounts with 1.5 inch urethane bushings. These mounts will then be permanently welded in the upper section of the old stock Ranger cross-member.

Today we did a priliminary markup without transmission installed to get an idea how things will fit. The oil-pan on the LS1 markup block has a rather long sump and required some cross-member cutting. The small cutouts will be boxed in and should be returned to stock strength.

[klaus]

Here the cross-member is not cut and you can see the oil-pan touching things. The engine is too tall and needs to drop.

[klaus]

cutting time

[klaus]

engine sits now a bit lower...

[klaus]

some updated images of the current status of the cab cage.

[jeff]

Hooray for updates! So what's next?

Aloha

[jeff]

What trans?

Aloha

[klaus]

What trans?

Aloha


Tremec TKO600 (http://www.tremec.com/English/products/TKO.asp)

http://www.5speedtransmissions.com/TKO-600_GM500px.jpeg


Good info here: http://www.5speedtransmissions.com/dimensions.html

[DEZERTBOUND]

Hey Klaus I was sent these pic's today on the Desert Dirt Dogs race truck. No ajoining text. But the guys are still working on it. My Bajabug is taking all my spare time. If I get more info I will pass it on...

[lvrudy]

Klaus, I have read all of your updates and i must say that is one sweet build you got going on...Exactly what i am wanting to start building!!!

Were you able to finish the project at wizard in the 6 months or did you have to rent a space from them???

What is the tally of the build up to date and if you could break it down into a couple of different sections like suspension, chassis,dash,wiring,drive train etc... that would be great...Just want to see if I even have the wallet for such a thing...

[Mcarlson1]

How much more does the LS1 weigh than a 302? Also how much did the engine have to be lowered and are you moving it back at all? And was it a big task to get that motor fit and will the be any major clearence problems that you will have to do some trimming or modifying on?? Lookin good by the way!!

[alwazonedge]

How much more does the LS1 weigh than a 302? Also how much did the engine have to be lowered and are you moving it back at all? And was it a big task to get that motor fit and will the be any major clearence problems that you will have to do some trimming or modifying on?? Lookin good by the way!!

maybe i can help a bit. ive done some of the ls to ranger swaps, and theres definately some required to make it fit. how much is dependant on what you want out of it. mike from esb taught me to make your own bushing mounts for the motor to eliminate rumble and stock location issues after fabbing, plus it creates a sturdier and more capable way of placing the block. on the rangers theres two way to overcome the crossmember issues wiyth the motor, mod the pan or mod the member. i prefer to mod the member if yer gonna keep it or just eliminate it alltogether and use your own/fab one up, of course not forgetting to double measure and temp weld everything to ensure theres no dimension loss through the process. pushing the firewalls on these is pretty simple for a full build, i like to go to new pedals and all, but for someone needing to maintain the fore-aft location of the motor, to fit the 350 all you need to do is pull it a bit around the bellhousing and get rid of the stock radiator and coolers, either in the bed the thing or move it a bit with an aftermarket pusher fan. hope i helped. oh, and in fullsize powering the mini fords, dont forget the housing for the coils in the frame has to be trimmed on BOTH SIDES to clear. made that mistake once. nice one jan.

[klaus]

Thanks for the post,

The way I started was to set the engine as low and far back as possible. I left room for bell-housing bolts to be removed with the engine in place (trans swap down the road). The cross-member got trimmed a little bit to give it the extra 2 inches of lowering. I know that the LS1/2 come with different oil-pans. I am not sure what I have on my markup block but i worked around it. The pan seems to be very flat and I am happy with it.

The suspension will be a coil over shock type and be away from the engine. I am not worried about that at this time.

The radiator will be in front and there is plenty of room for it with the LS1 in place.

I abundant the entire engine fitment until I have the correct transmission in my hands to fit it all at once (motormounts and transmount).

Not sure about the weight difference between a LS1 and 302. I guess the LS is lighter as they come with aluminum block and heads while the Ford302 typically is an iron block with iron heads unless you use aftermarked aluminum heads.

The entire project is on hold right now as the Wizard School closed its doors. A new business will be opened by some of the former owners that will allow me to continue the project. Once they open the doors to the new shop it will be announced here on this forum.

[CaptinCrash]

what when did wizard close

[AaronDixon]

what when did wizard close

Check out this thread:

http://dezertrangers.com/cgi-bin/ib/ikonboard.cgi?;act=ST;f=1;t=56502

[Devin J]

Thank god I didn't follow my dream of learing things at that school. I would be pretty pissed if I left Oregon for that hole! I apologize in advance to Klaus for a thread hijack, and for typing a bad word.

[Brock_Beeson]

what the new shop gonna be called?

[alwazonedge]

and whens it gonna open?

[klaus]

Some updates on my project. I moved my truck out of the Wizard school to a friends shop where its just sitting around and collecting dust at the moment. The former Wizard staff was very accommodating to me and helped me out as much as possible to get my truck and belongings out of their storage after they closed doors.

I keep hearing about disappointed students and feel their pain. The best advise from me is to contact the people behind the Wizard school and ask for a solution. Trash talking here or elsewhere doesn't help anyone.

On my truck the next step will be to get it "burned in". I have made arrangements with the guys at Camburg to get all tubing that is just tagged welded and also to install their new I-Beam kit. Once that happens there will be more updates and pictures.

[charlie_brown]

there new beam kit is sick. post pict as soon as posible.

[Firefighter26]

Man you should call Troy Johnson at the fab School. He is a really kool guy, maybe he could lend you a hand so that your bad @#$ truck can get done.

[WannaB-class5]

Klaus, any word or updates on your project? When you say Camburgs new beams do you mean the fully fabbed ones with the heim as the upper?

[alwazonedge]

klaus...
honest question, why beams? looks like a 97 or up chassis, goin v8, you have all the advantages of buildin yer own truck.....and yer usin a camburg beam kit? im confused, not that they dont build great stuff, but for the money why step into beams when you could get just as much out of a fabbed up arms setup? especially with the weight of the v8, isnt it a step backwards? just curious, also thanks for the tip on the wiring awhile back, i got the problem fixed

[RocketMan]

He may want travel and not too much track width.....just a thought

[alwazonedge]

yah, makes sense, but after tubbing the new motor in and pushin everything back it would be about the same. the beams realistically get strapped right aroun 17-23 inches right? you can get that out of a custom arm setup. just thought if i were gonna go through the effort of tubbin the motor back id go ahead and throw some badass jarms and lowers on it.track width and class rules were the only real reasons i could think of to go beam.

[Vance_Miller]

where would i be able to find a rear end kit like that for a 1990 chevy 1500?

[tre5]

http://dirt-tech.com/hubs_brakes_axles.html

[Miniracer]

How Much Travel Is It Going To Have?and Whats Its Wheelbase Can You Post Some Pics?

[klaus]

I haven't posted here in a long time since there is not much of an update.

The truck is in storage at a friends place and I am probably overstaying my welcome by now. I constantly look for parts and collect them as I see them in our own classifieds. I keep my eyes open on other peoples projects and collect ideas. Take pictures of things I like.

Once you loose momentum on a build its hard to get back into it. Often I save some cash up to be invested (burned) in the project just to end up spending it on those speed bumps in life. This project is meant to not be built on debt so that makes it tough for me.

My Turnkey LS2 engine should arrive shortly and hopefully that will give me an incentive to revisit the project.

I'm in talks with two shops to get the truck finished so hopefully I can be part of the Mike's Sky Ranch Pre-Baja race party scene. lol

[partybarge_pilot]

I'm in talks with two shops to get the truck finished so hopefully I can be part of the Mike's Sky Ranch Pre-Baja race party scene. lol

Oh come on Kleezy, you know the Moostang would rally the Mikes road!

[fishd00d]

Oh come on Kleezy, you know the Moostang would rally the Mikes road!

The Moostang isnt rallying much lately lol

Get that Ranger done Klaus!!! Just you might have a hard time finding someone to ride with you in it hahahha

[Steven_Tolbert]

Any updates???

[klaus]

Yeah...
Truck was in storage at a friends place for a long time. Now its at my boys Aries place and he will finish most of it.
I am collecting parts as I see them in our classifieds.

Once there is more to show for updates will be posted.

[pjc]

Klaus, your Ranger is likely gonna be a lot more top heavy than a TL..

HINT!

[klaus]

Update:

- Picked up a mock-up Mastercraft Po4 Suspension Seat from Mastercraft. Thanks Robby for the hockup.
- Turnkey Engines gave me a mock-up LS2 block with cylinder head and oil pan while the real engine is on order.
- Got 90% of my rear end parts together. Missing Rotors, Calibers and the correct drive plates.
- Arie took the roof off to weld inside the cab and also started on welding up the rear part of the cage.

Overall slow but solid no short cuts progress.

[Mike @ pit b]

How about some pics. if you get the chance?

[klaus]

Yeah I meant to take some updated pictures last Wednesday when I went over to the shop but left the cameras in the office. Will do next week. The way the roof got cut off is very slick and clean and worth sharing.

[Prerunin554]

Yes, pictures please! I am collecting parts here as well for my ranger, hopefully you have stopped scouting the classifieds here for a while, i need parts too :D


I should be ready to start with it in the next 2 months....

[fab101]

Klaus, I am excited that you are back in action on the Ranger... can't wait to see these updated pics!

[Mike @ pit b]

Any updates or pics?

[Richie_Bobby]

Pics??

[charlie_brown]

Hello Hello Hello is there anybody out there? Dead thread.

[Ozzie M]

Maybe come on lets see the progress looks bad a ss so far

[klaus]

little progress. Bought a used 4L80 today though.
I am just lining parts up.

Sad

[charlie_brown]

i will go by a few DP7 dvd's while i am still working. will that help?

[JoeyD23]

Tell Arie to snap some pics Klaus! Lets see some of his work....anyone that Knows Arie knows he can lay a mean bead!!!

[milktoast]

You build looks great! I'm a newbie and gathering up as many ideas (particularily cab cage design) as I can and all your pix are a great help. I had a question about your cab cage in regard to SCORE rules. I'm having a tough time interpreting their rules for cage design (their little picture leaves a lot to be desired) and their fractioned sentences make it tough to figure out just what they are requiring. In the 2006-2010 rule book p.33 they say "Upper main, front, rear, and lateral rollbar hoops must be made in one piece without joints". I figure that I must be misinterpreting what they are saying, since you are building yours score legal and it looks like you are using welded joints for most of the cab.