Phase 5 - Rear frame/cage build

[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]

more pictures

[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]

mas pictures.. .

[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.