Ranger Prerunner Build Part 3: Fuel Cell Cradle and Shock Mount Innovations

October 12, 2024

Progress on the Ford Ranger Build

A blue truck in a garage is being modified with a metal roll cage frame installed. There are tools and equipment visible around the work area.

The ongoing transformation of the Ford Ranger into a highly customized vehicle continues to be an impressive endeavor. The latest update highlights significant progress in the project, showcasing advancements in the rear structure and overall framework. Key components have been meticulously crafted, and the process involves a blend of precision engineering and creative design. The build is particularly notable for its focus on structural integrity and aesthetic appeal.

Building the Fuel Cell Cradle

A person wearing a black hat and shirt stands next to a metal structure with tubing and a fuel tank labeled Fuel Safe Systems in a garage setting with various tools and equipment in the background.
A man stands beside a vehicle frame with exposed roll cage and suspension system in a garage. The garage has equipment and supplies on shelves and the walls are wooden.
Metal framework with welded joints, part of a vehicle's chassis structure, features a visible Wilwood brake caliper and suspension components.

Design and Construction

The recent work has been centered around constructing a fuel cell cradle. The base of this component was initially crafted on a workbench with the fuel cell placed upside down. This method ensured that the structure was precisely tailored to fit the unique shape of the fuel cell. A notable feature is the inclusion of a single tube with a bend, aligned to the fuel cell’s profile, offering a clean and strong design.

Structural Considerations

Person standing in a garage next to a metallic fuel tank with
Person working on a metal tubular frame structure in a garage workshop environment.

In crafting the fuel cell cradle, emphasis was placed on using miters rather than open-ended tubes. This approach not only enhances the visual appeal but also strengthens the structure. The integration of closed-off miters ensures a robust framework, which is crucial given the weight and load the cradle must support. This meticulous attention to structural details underscores the project’s commitment to both form and function.

Integration with the Chassis

Positioning and Alignment

A person wearing a cap and black shirt is working on a metal frame structure in a garage. The garage has various tools, parts, and equipment on shelves and walls, including a drill press and car grille covers. The structure appears to be part of a vehicle chassis with visible shocks and suspension components.
A metal framework structure on a workbench in a garage with tools and equipment in the background.

Positioning the fuel cell within the truck’s chassis required careful planning. Factors such as the wheelbase and the placement of the spare tire were taken into account to ensure that the vehicle’s proportions remained visually balanced. The fuel cell’s placement also facilitated the incorporation of auxiliary components, such as a jack, without compromising space or design integrity.

A partially assembled off-road vehicle with a visible metal roll cage and exposed rear suspension is in a garage. The area is cluttered with tools, equipment, and boxes. A fuel cell labeled

Connecting Sections

The integration of the fuel cell cradle into the truck’s chassis was achieved through strategic placement and alignment of various tubes. Each connection point was meticulously welded, ensuring a seamless transition between components. This careful attention to detail not only enhances the structural strength but also contributes to the overall aesthetic of the build. Additionally, the use of 3/16 plate work is planned to further reinforce the connection points.

Innovative Shock Mount Design

Mocking Up Shocks

Person in a garage or workshop examining a metal roll cage structure on a vehicle with various tools and equipment visible in the background.
Metal tube chassis construction in a garage setting with tools and equipment in the background.

The process of incorporating shock mounts into the build required a strategic approach. The shocks were temporarily mocked up to assess the best placement for the mounts, which will be crucial for vehicle performance. The design considers both visual appeal and structural integrity, ensuring that the mounts will not only look good but also withstand the rigors of off-road use.

Structural Reinforcement

Once the shock mounts are in place, they will add another layer of structural reinforcement to the vehicle. The design of the mounts will ensure they tie into the existing framework seamlessly, providing additional support to handle the weight and stress of the vehicle’s suspension system. This reinforcement is critical, especially given the demands of high-performance driving conditions.

Progress and Challenges

Efficient Workflow

Despite the complex nature of the project, the build has progressed efficiently, with significant advancements made within a short timeframe. The meticulous planning and execution have allowed for rapid development, with key components pre-fabricated before the truck’s arrival. This efficient workflow has been instrumental in maintaining momentum and achieving milestones quickly.

Overcoming Design Hurdles

Throughout the build, several design challenges have been encountered and overcome. The unique demands of the project, coupled with the desire for a clean and robust design, have necessitated innovative solutions. Each challenge has been addressed with a combination of technical expertise and creative problem-solving, ensuring that the final product meets both functional and aesthetic goals.

The Importance of Customization in Vehicle Builds

A person wearing a black cap and shirt stands in a garage near a metal frame structure on a workbench. The garage has tools and materials on shelves, and the door is open to a view of greenery outside.
Two people in a garage or workshop next to a partially constructed vehicle frame with exposed suspension components and visible welding equipment.

Vehicle customization is not just about creating a unique aesthetic; it’s about enhancing performance and utility. The Ford Ranger build exemplifies this by focusing on structural modifications that support additional weight and improve handling. Custom builds allow for tailored solutions that meet specific needs, such as off-road capabilities or increased payload capacity.

In the broader context of automotive customization, projects like the Ford Ranger build demonstrate the value of skilled craftsmanship and engineering. They highlight the importance of considering both visual design and structural integrity. Custom builds also provide a platform for innovation, allowing builders to experiment with new techniques and materials that can influence future automotive design.

As the Ford Ranger project progresses, it continues to set a benchmark for custom vehicle builds, showcasing what can be achieved when creativity and technical expertise are combined. The ongoing updates provide insight into the complexities and rewards of automotive customization, offering inspiration to builders and enthusiasts alike.

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