Ranger Prerunner Build Part 8: Chassis, Suspension, and Interior Modifications Explained

October 21, 2024
A teal modified truck with large off-road tires and no front body panels is in a garage. The vehicle has a custom front suspension and roll cage typical of a prerunner. A red arrow points to the suspension area. Tools and equipment are in the background.

The current project revolves around a detailed update on the build of a Ford Ranger prerunner, a custom off-road vehicle. This type of vehicle is often used in desert racing and is noted for its ability to handle rugged terrains. The prerunner is being extensively modified, focusing on both performance enhancements and aesthetic improvements. The build involves fabricating and installing custom components, optimizing its suspension, and retrofitting engine components, among other things. This particular article will delve into the specifics of the modifications made to the chassis, suspension, steering, and other pivotal parts of the vehicle.

Chassis and Structural Modifications

Enhancements and Reinforcements

A partially assembled prerunner vehicle frame with exposed engine components, suspension system, large tire, and visible frame sections positioned on jack stands in a garage setting.
Person standing in a garage next to a workbench with vehicle parts including shocks and coils, a truck tire, and components for a prerunner vehicle. Shelving and tools are visible in the background.

The structural integrity of the Ford Ranger has been a significant focus during the build. Initially, the front of the truck was stripped down to its factory firewall and frame rails. The primary upgrades included the addition of a custom beam kit, which has now been fully assembled and installed. This kit enhances the vehicle’s off-road capabilities by allowing for greater wheel travel and improving overall durability.

Building the Cross Member

A new tubular cross member has been crafted to replace the factory variant, which was deemed a restriction for the new suspension system. This custom cross member is fabricated using inch and three-quarter 120-wall tubing, providing a robust and flexible platform for the engine and suspension attachments. This change facilitates better handling and provides greater support for the modified engine placement, which has been moved back by approximately six inches for optimal weight distribution and center of gravity.

A person is adjusting or inspecting a suspension component next to the exposed engine and chassis of a prerunner vehicle in a garage setting.
A person is working on the frame of a prerunner vehicle in a garage. The front suspension, engine, and other mechanical components are visible. The garage has tools and equipment in the background.

Firewall and Engine Positioning

With the engine shifted back, significant alterations were made to the firewall to accommodate the new setup. This adjustment not only optimizes weight distribution but also enhances cockpit ergonomics, allowing for a more comfortable and practical driver experience. The backside of the transmission was previously constrained, requiring a two-piece drive shaft, but with the new positioning, a single-piece drive shaft is now feasible.

Man in a garage working on a prerunner frame with visible roll cage, engine, and transmission.
Person in a workshop stands next to a table with automotive parts, including King coilover shocks, a radiator, and other tools. A large garage door is in the background, and equipment is scattered around the workshop.

Suspension and Steering Systems

Custom Steering Setup

The steering system has undergone a thorough revamp to improve precision and durability. The steering box was repositioned to accommodate the straight tie rods, which were fabricated using inch and a quarter 250-wall tubing for enhanced strength. The custom pitman arm was hand-built to provide a double shear configuration, ensuring the steering system’s robustness. This setup minimizes deflection and maintains steering stability across different terrains.

Beam Suspension System

The prerunner now sports a center-mounted radius arm setup, facilitating improved suspension geometry and handling characteristics. The design ensures minimal bump steer and optimal caster angles throughout the suspension cycle, important for maintaining control over uneven surfaces. Custom beam mounts, designed in SolidWorks, were adjusted during assembly to ensure a perfect fit, underscoring the importance of precision in custom builds.

Chassis structure of a vehicle with metal tubing, a gearbox, and a differential housing, likely from a prerunner truck, visible suspension components with blue coil springs in a workshop setting.

Cab Interior and Controls

Driver Ergonomics

Inside the cab, modifications were made to improve driver ergonomics. The repositioning of the engine and transmission resolved prior issues with the shifter’s reach, aligning it more naturally with the driver’s seating position. This change, alongside new pedal placements, offers a more intuitive and comfortable driving experience, crucial for long off-road excursions.

A person stands beside a blue off-road vehicle in a garage. The vehicle is being converted to a prerunner with roll cage modifications and a visible transmission. The garage has tools and equipment scattered around.

Custom Interior Fabrication

The interior is being reimagined with custom panels and seat mounts to accommodate the vehicle’s new layout. The removal of the factory flooring and firewall allows for a bespoke interior solution that is both functional and visually appealing. These adjustments will also ensure that all mechanical components are easily accessible for maintenance and adjustments.

The interior frame and transmission setup of a vehicle being modified for prerunner use, with visible roll cage, transmission, and a partially assembled engine.

Rear Assembly and Storage Solutions

Storage and Weight Distribution

The rear section of the prerunner has been meticulously planned to ensure optimal weight distribution and utility. A Jack mount has been strategically placed to balance weight distribution, and custom containers for fluids and other essentials have been crafted to fit within available spaces. These elements are designed to be both practical and aesthetically pleasing, contributing to the vehicle’s overall efficiency and balance.

A person in a garage is standing next to a partially assembled truck. The truck has exposed engine components and off-road tires, with a Prerunner build visible in progress. Various tools and equipment are on shelves in the background.

Fuel System and Electronics

The new fuel system is positioned at the rear, a choice made to improve weight distribution and ensure stability during high-speed maneuvers. Additionally, the fuel pump and filters have been discreetly integrated into the frame rails, leaving room for future electronic upgrades and facilitating easy access for maintenance tasks. The battery setup is designed to provide balanced power distribution, with considerations for future electronic enhancements.

Person standing in a garage near a partially assembled off-road vehicle chassis with visible tires and suspension components. Shelving with tools and supplies in the background.

Challenges and Considerations

Engineering and Design Challenges

The project has faced various engineering challenges, particularly concerning space constraints and component clearance. The narrow track width of the ranger required precise engineering to ensure that components like the suspension and steering systems fit correctly without sacrificing performance or safety. These challenges necessitated innovative solutions, such as clocking the top caps of shock absorbers to prevent hood interference.

Future Considerations

A custom-built Prerunner truck with its front end exposed, displaying a high-performance engine and suspension system. The vehicle is supported on jack stands in a garage, surrounded by tools and equipment.

While the current build is focused on maximizing the performance of the existing V6 engine, considerations have been made for future upgrades. The radiator and engine mounts are designed to accommodate a potential V8 engine swap, ensuring that the vehicle remains versatile and adaptable to future needs. This forward-thinking approach ensures that the truck can evolve alongside the owner’s ambitions and requirements.

This comprehensive build process showcases the intricacies involved in crafting a high-performance prerunner. Attention to detail, precise engineering, and a commitment to quality have driven the modifications, resulting in a vehicle that is not only capable of conquering the harshest terrains but also tailored to the specific needs and preferences of its owner. As the build progresses, it will continue to push the boundaries of custom automotive engineering, setting new standards in the off-road community.

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