DoubleMint: A Ranger Story

Discussion in 'Build Threads' started by Andy J., Jan 15, 2018.

  1. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    I just picked DoubleMint up from @ProbablyBroke this weekend. Lots of plans, but you know what they say about plans. For now, the goal is to get her registered for street duty and work out any quirks while learning what she's capable of in current form. I intend to run a single set of tires because I'm too lazy to swap them every trip. I have no idea how either of these tires do on the street, so I'll give them both a try an then decide whether to run one or the other (or something else).

    Here's the spec sheet (copied from the sale ad):

    1994 Ranger XL
    174,000 miles
    4.0 OHV fuel injected
    M5od manual 5 speed trans
    Borg Warner bw1354 manual t case

    36x13.5x15 bias SUPER SWAMPER TSL IROKS on Mickey Thompson classic bulletholes, about 70% tread
    Balanced with airsoft bb

    37x12.5x16.5 Goodyear MTs on procomp steelies, between 80% to 50% tread depending on tire. One has a patch. Balanced with airsoft bb

    Front axle
    5 lug High pinion Dana 44 from a late 70s f-150.
    4.88 Yukon gears
    Detroit locker
    3/8" ruff stuff diff cover

    Rear axle is a Ford 9" from a bronco.
    Rear disc brake conversion
    4.86 gears done by Carolina Axle and 4x4
    Detroit locker
    3/8 pinion guard

    Steering is 1.5" DOM with Heims.
    Saginaw power steering pump conversion with remote reservoir
    Hydraulic assist ram

    Suspension is WH coils up front with extended radius arms.
    Rear is bastard pack springs on a 3" block

    Summit 10 ish gallon fuel cell with stock fuel pump in the cell.
    3/8" steel rear bumper
    Kc daylighters


    Here's the original build thread by @GrnRanger:
    Ranger SAS

    Just loaded up for the trip home:

    Double mint.jpg
     
  2. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    9A6E1DF4-39B8-4D25-AFCC-E226104070A6.jpeg Drove her to work. The plan was to get the safety inspection done today but I’m not sure the shop will be open.
     
  3. DSM Turbos

    DSM Turbos Well-Known Member

    Joined:
    Feb 25, 2006
    Location:
    Raleigh, NC
    Good to see you already with a rig!
     
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  4. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    Did you get your running issues worked out yet or you just going to jump right to the propane conversion? You gotta get that fixed so we can go break something else.
     
  5. DSM Turbos

    DSM Turbos Well-Known Member

    Joined:
    Feb 25, 2006
    Location:
    Raleigh, NC
    Its fixed now. It needs a anti wrap bar put on it before its wheeled again, and a few other things fixed. With work and other stuff, I won't likely be able to wheel until April now, so hopefully the propane and all will be on by then anyways.
     
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  6. GrnRanger

    GrnRanger Well-Known Member

    Joined:
    Jun 2, 2008
    Location:
    Raleigh
    congrats @FrontPorchFab
    good to see another nc4x4 member end up with it.
     
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  7. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    No actual tech here, but I have a small pile of shiny new transfer case e-brake parts. I got the rotor and caliper from Parts Mike (great service and everyone else had a 3 week back order) and the Lokar parts from amazon. Im going to use a Lokar cut to length cable between the caliper and hand brake.

    7F2FFDB4-BBC0-4B11-9190-402A998569F0.jpeg
     
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  8. seed60

    seed60 Well-Known Member

    Joined:
    Aug 14, 2008
    Location:
    Mooresville, NC
    That's exactly what I need. Can't wait to see more.
     
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  9. ProbablyBroke

    ProbablyBroke does not torque to spec

    Joined:
    Nov 7, 2012
    Location:
    Charlotte
    Dang, that's a very nice set up.
     
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  10. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    Here’s my plan for mounting the caliper. I don’t know if my scribble is legible to anyone else, but I wrote out my measurements and expectations for the caliper function. I also included a pic of the caliper for reference. I read somewhere that this caliper was originally from a golf cart. If that’s true, it probably wasn’t designed for a .25” thick rotor. I found that to get .125” of float, I’m going to have to put in a .15” spacer and get longer bolts to hold it all together. Does .125” of float sound about right?

    I’ll get actual measurements from the truck tomorrow to design the brackets from and get someone to burn them out and bend them up.

    0236C41D-A806-48C9-9975-5396BC684F50.jpeg B63AED54-7D68-48DB-AF5E-D7F43EB5EA85.jpeg 562B192F-8C01-46AE-B398-4C9E308A83D4.jpeg
     
  11. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    Once I crawled under the Ranger and started taking measurements, I quickly realized that my not-to-scale sketch was very NTS. After regrouping this is what I came up with. I also realized that I’m going to have to cut out a section of a body stiffener and probably massage the floor pan a tad to get the rotor to fit. It’s going to be close, but I don’t think I’ll have to cut into the cab. The next step will be to mock this up out of cardboard or something to test fit the parts and figure out the best location for the cable end bracket.

    6CC6C99B-A341-4CF7-BD28-D6B2032AAC05.jpeg
     
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  12. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    I had 30 minutes free so I mocked this up. It probably wouldn’t hold up to trail abuse, but it should be gtg for mall crawlin’!

    DCC72799-D3F0-4016-A410-FDA65AFA29B5.jpeg
     
  13. seed60

    seed60 Well-Known Member

    Joined:
    Aug 14, 2008
    Location:
    Mooresville, NC
    Too legit to quit! Might as well go ahead and make 2.

    Do you think it would clear with a 3" body lift?

    Edit: After some googling I see how the lokar cable works. Pretty cool. Wonder if I could hook it up the factory ebrake cable?
     
    Last edited: Feb 7, 2018
    Andy J. likes this.
  14. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    Yes on both counts. There’s about 1” of interference so you should have plenty of room with a 3” body lift.

    The only reason I didn’t go with the factory ebrake setup is that I don’t have one. The pedal mechanism and cables were removed from Doublemint in a previous life. I did consider pulling some junkyard parts, but it was cold/rainy/snowy and all my tools are still in storage from my cross-country move. Given a choice, I prefer a hand brake to a foot brake anyway. Having a single short cable will also (hopefully) minimize routing issues and cable stretching.
     
  15. JSJJ388

    JSJJ388 GREEN GREMLIN

    Joined:
    Aug 31, 2016
    Location:
    HAMPTONVILLE, NORTH CAROLINA
    Solidworks?
     
  16. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    NX. It’s arguably more powerful but I prefer the user interface of Solidworks.
     
  17. JSJJ388

    JSJJ388 GREEN GREMLIN

    Joined:
    Aug 31, 2016
    Location:
    HAMPTONVILLE, NORTH CAROLINA
    Never heard of NX. Ill have to look into it. I started in solidworks and now work in Tekla as well as free cad.
     
  18. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    I used Solidworks for about 8 years and NX for 5 yrs. As far as CAD goes, they are pretty similar. NX shines when coupled with the Siemens PLM system. Back when I used Solidworks, they didn’t have a very good PLM system. I’m sure it’s been improved since I last used it though.
     
  19. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    I must have been drunk when I measured the first time because I was off by a couple inches. I have no idea how I screwed it up that badly, but I’m glad I made that cardboard cutout! I fixed it and made a second cutout that actually worked. Made a couple minor tweaks and am now ready for production! That long tab on the left is to hold the cable end and the tab on the right is for a return spring.

    D63E9C56-A89F-4C99-8A0F-61840DB5779C.jpeg
     
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  20. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    @seed60 Due to a bit of impatience on my part, I ended up with two sets of mounting brackets. Let me know if you want a set.

    59A8B31E-9D7C-44C4-BAD1-2D0E62645519.jpeg

    Edited to add: Hopefully I’ll get this whole setup installed in the next week or two. We are in the middle of moving, so progress has been slow.
     
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  21. seed60

    seed60 Well-Known Member

    Joined:
    Aug 14, 2008
    Location:
    Mooresville, NC
    Get a chance to install that bad boy yet? How'd it turn out?
     
  22. ProbablyBroke

    ProbablyBroke does not torque to spec

    Joined:
    Nov 7, 2012
    Location:
    Charlotte
    I need updates
     
  23. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    Sorry, I did say this was going to be slow right? Between work travel, kids, and a house remodeling project, I've not spent much time working on DoubleMint. Since last post, I've painted the mounting brackets and drove around the neighborhood once. The big stuff is mostly done on the house now, so hopefully I can carve out some time and get this going.
     
  24. Andy J.

    Andy J. wheels for beer

    Joined:
    Nov 5, 2005
    Location:
    Winston
    I had a couple hours last night, so I chopped the trans tunnel and got the rotor installed. Might have cut the hole a little bigger than needed, but access to cut the backside of the body cross member with the t case installed kinda dictated the size. Also put the other tires on.

    new shoes.jpg Rotor in cab.jpg Rotor under.jpg
     
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  25. seed60

    seed60 Well-Known Member

    Joined:
    Aug 14, 2008
    Location:
    Mooresville, NC
    Awesome. Table saw, cheese grater, french fry maker mod!
     

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