Ranger Prerunner Build Part 5: Rear-End Modifications and Enhancements

October 21, 2024
A truck chassis with a tubular frame is shown, featuring a sway bar and hydraulic bump stops highlighted. The suspension system includes coilover shocks, and the setup appears to be intended for a prerunner vehicle modification.

In the latest update on a custom Ford Ranger build, the team at Vital Designs, led by Christian, has been working diligently on the truck’s rear half. This project involves intricate modifications and custom designs aimed at enhancing the vehicle’s performance and functionality. The focus of this update includes installing bump stops, a sway bar, a fuel cell, and preparations for the jack and bedsides. Each component requires careful consideration of design, functionality, and ease of maintenance.

Installing the Bump Stops

Mounting and Design Considerations

The installation of bump stops is a crucial element in absorbing shock and protecting the suspension system during off-road excursions. The team opted for a simple, clean boxed mount design. The bump stops were mounted without the Delrin pad initially to facilitate better alignment. Once the shocks were fully bottomed out, the pads were reattached to ensure proper spacing between the bypass and the coilovers. This meticulous setup ensures that nothing bottoms out, providing a more reliable and efficient suspension system.

A person in a gray hoodie and black cap stands in a garage next to a metal fuel cell labeled for a Prerunner. The background has auto parts, tools, and shelves with bottles and containers.
Close-up of a prerunner chassis emphasizing welded tubular structures, a suspension component, and a finger pointing at a nut on the frame.

Challenges and Solutions

One of the challenges faced was maintaining the alignment and stability of the bump stops during installation. By removing the Delrin pad, the team could achieve a more precise fit, reducing the potential for misalignment. This method simplifies the process, especially for those tackling such modifications for the first time. Additionally, the bump stops were designed to be a consumable, replaceable part, allowing for easier maintenance and increased longevity of the suspension system.

Custom Sway Bar Installation

Addressing Packaging Constraints

A person wearing a gray hoodie and cap is standing beside a metal-framed structure with a mounted fuel cell in a garage. Various tools and automotive parts are visible on shelves in the background.
A person in a garage workshop stands next to a custom metal truck frame for a prerunner build, pointing at a fuel cell on the chassis. Shelving with tools and equipment is visible in the background.

The sway bar’s installation was another complex task, primarily due to the limited space available. The decision to mount the sway bar at the front was driven by packaging constraints, as the original design concept had to accommodate spare tires on the sides of the fuel cell. This change necessitated a unique approach to fitting the sway bar within the available space.

Design and Functionality

To ensure optimal performance, the sway bar’s design had to align with the overall aesthetics and functionality of the truck. The team used a two-inch, 120-wall tube to mount the torsion bar, incorporating Delrin bushings for smooth motion. The sway bar’s performance is affected by the torsion bar’s rate, arm length, and angle, all of which were carefully considered to prevent binding and ensure maximum wheel travel.

Person in a garage working on a prerunner chassis with exposed metal framework, fuel cell, and suspension components, tools and automotive supplies in the background.
Person adjusting the suspension components on a prerunner truck chassis with visible shocks, springs, and a tubular frame structure.

Fuel Cell Mounting

Design Approach and Challenges

A person in a gray hoodie and black cap is standing next to the metal framework of a prerunner vehicle in a garage with shelves holding automotive supplies in the background.
Close-up view of a metal welded roll cage structure for a Prerunner vehicle, showing suspension components, a shock absorber with a blue reservoir, and tubular frame elements with a person's hand pointing at one section.

The fuel cell, another essential component, was mounted using a plate-based design, departing from the traditional tube structure. This decision was made to simplify the installation and improve the packaging within the truck’s rear end. Proper placement and support for the fuel cell are critical, as any structural weakness could lead to failure over time.

Ensuring Durability

The fuel cell’s bottom is supported by the truck’s structural tubes, preventing it from bowing out due to the load. This approach ensures the longevity of the fuel cell, protecting the plastic bladder from stress and potential cracking. The design also facilitates easy removal for maintenance, reflecting the team’s focus on practical, user-friendly solutions.

Additional Modifications and Future Plans

Coilover Reservoir Mounting

A person in a grey hoodie and black cap is standing next to a partially assembled Prerunner chassis, pointing at the braking system. The garage background includes shelves with auto parts and equipment like a drill press.
Person in a garage with a custom-built off-road prerunner frame showing suspension components and a fuel cell. Shelves with various automotive products and tools are in the background.

The team has also mounted the coilover reservoirs using clamp-style mounts, which are preferred for their durability and clean appearance. This method prevents damage to the reservoirs and ensures they remain securely attached to the chassis.

Jack and Bedside Mounting

A person in a gray hoodie and black cap stands next to a blue truck's custom suspension setup in a garage. The suspension includes dual coilover shocks and visible structural tubing. Shelves with various bottles and containers are in the background.
Man inspecting the suspension components of an off-road prerunner truck in a garage, focusing on the shocks and chassis. Various automotive supplies are visible on shelves in the background.

Christian has initiated the design for a jack mount, which will be discreetly housed in a sealed compartment. This design protects the jack from environmental wear while keeping it easily accessible. Additionally, the truck will soon feature mounted bedsides, which are being designed to seamlessly integrate with the rest of the vehicle.

Looking Ahead

As the build progresses, the focus will shift towards finishing the cab and starting work on the front end. The goal is to complete the major structural elements before delving into the more intricate details, such as panel work and final touches. This approach allows for significant strides in the project’s development, keeping the build on track for future testing and validation.

The meticulous work being done on this Ford Ranger is a testament to the importance of combining design aesthetics with functional engineering. As the build continues, it will serve as a valuable reference for those interested in custom vehicle modifications, offering insights into the challenges and solutions involved in such a complex project.

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