Budget Off Road Rig
05-09-2014, 12:42 AM
#1
Budget Off Road Rig
So I've decided to make a build thread outlining the future of modifications to my truck to make it more off road worthy. But here's the kicker, I'm a high school student, making minimum wage on a part time job, so money isn't exactly dripping out my underpants. So I've decided to make a budget off road rig build basically to show anything I am able to do on my budget. I believe that anything reasonable can be done on a budget, you just need to understand and accept the fact that you will be using a lot of Harbor Freight stuff. 
My goals:
1) Make it road safe
2) Keep it in my budget
3) Make it unique
4) Make it a great off road rig, that pairs as a daily driver and work truck
My truck is a 2002 F150 XL, 4.2, 2WD, extended cab. ~275,000 Miles as of now.
I have a small idea of priorities of mods I'd like to make to the truck based on prices, necessity, and skill level. Also, some of these aren't mods, they're tools that would be helpful to acquire over time. Some of these modifications are relatively simple and easy, and the later projects are quite complex. However, anything I put on here as an idea, I believe I can achieve. Keep in mind that the future mods I am planning won't all happen soon. Many may take months, maybe even a year or more to get around to.
Things I have already done
-Windows tinted: Unknown cost
-Expedition Wheels with BFG Rugged Terrain tires: ~$200+$800= $1000
-Screw in style coil spacer with 1" lift: ~$25
-Behind the grille lights: ~$15 from junk yard
-PTM Honeycomb Grille + PTM Bug Guard: ~30
-Window visors: Price unknown
-Weatherguard Toolbox: Free, grandfather wanted to get rid of it
-Flowmaster 40 Si/So with Lightning style exit: ~$80
Future Mods
-12,000 lb winch + custom bumper: I've already gotten most of this done and it has been relatively cheap. I will post a response soon about how it is going to happen.
-New Battery: My current battery is doing fine, but it is long since due and I think a new one couldn't hurt. Better safe than sorry.
-Skid plates: Steel skid plates to protect oil pan and transmission fluid pan. This should cost almost nothing besides some steel and bolts.
-CB Radio: Very useful if buddies nearby are using CBs. Would make communication between trucks significantly easier.
-Engine rebuild: This is one of the first big projects. I will buy a junkyard 4.2, likely have the block machined, and do a rebuild on the engine. This is may end up not being cheap, but will certainly make a big difference going from a 275,000 mile engine to a rebuilt one.
-Solid Axle Swap: I have put over a year and a half of research into solid axle swaps and leaf sprung swaps alone, so I am confident I could do it today if I had the materials. I will likely be using a Dana 44 out of a 78/79 F250. These appear occasionally on craigslist for quite cheap, and would be the most beneficial mod of the ones thus far. I will fabricate all hangers, shackle mounts, and shock towers. And will use junk yard parts where acceptable and safe.
-Exocage: An exocage is essentially an exterior roll cage, that doesn't interfere with the interior or any moving parts of the vehicle, to protect the whole vehicle in the event of a rollover or low speed collision with an object on the trail. They're commonly made of chromoly steel tubing.
Useful tools to get along the way
-New box of tools to keep in truck
-Winch tree savers and ****** blocks.
-High Lift Jack
As I said, not all of this will happen soon. Some things later in the list may even take over a year to get around to the design phase. The mods will probably also come slow, and a high possibility of some other cheaper mods being done between.
If you have any suggestions for mods or feedback on my concepts, please let me know! I'm here to learn and share my experiences.
Somewhat recent pictures of the truck:
My goals:
1) Make it road safe
2) Keep it in my budget
3) Make it unique
4) Make it a great off road rig, that pairs as a daily driver and work truck
My truck is a 2002 F150 XL, 4.2, 2WD, extended cab. ~275,000 Miles as of now.
I have a small idea of priorities of mods I'd like to make to the truck based on prices, necessity, and skill level. Also, some of these aren't mods, they're tools that would be helpful to acquire over time. Some of these modifications are relatively simple and easy, and the later projects are quite complex. However, anything I put on here as an idea, I believe I can achieve. Keep in mind that the future mods I am planning won't all happen soon. Many may take months, maybe even a year or more to get around to.
Things I have already done
-Windows tinted: Unknown cost
-Expedition Wheels with BFG Rugged Terrain tires: ~$200+$800= $1000
-Screw in style coil spacer with 1" lift: ~$25
-Behind the grille lights: ~$15 from junk yard
-PTM Honeycomb Grille + PTM Bug Guard: ~30
-Window visors: Price unknown
-Weatherguard Toolbox: Free, grandfather wanted to get rid of it
-Flowmaster 40 Si/So with Lightning style exit: ~$80
Future Mods
-12,000 lb winch + custom bumper: I've already gotten most of this done and it has been relatively cheap. I will post a response soon about how it is going to happen.
-New Battery: My current battery is doing fine, but it is long since due and I think a new one couldn't hurt. Better safe than sorry.
-Skid plates: Steel skid plates to protect oil pan and transmission fluid pan. This should cost almost nothing besides some steel and bolts.
-CB Radio: Very useful if buddies nearby are using CBs. Would make communication between trucks significantly easier.
-Engine rebuild: This is one of the first big projects. I will buy a junkyard 4.2, likely have the block machined, and do a rebuild on the engine. This is may end up not being cheap, but will certainly make a big difference going from a 275,000 mile engine to a rebuilt one.
-Solid Axle Swap: I have put over a year and a half of research into solid axle swaps and leaf sprung swaps alone, so I am confident I could do it today if I had the materials. I will likely be using a Dana 44 out of a 78/79 F250. These appear occasionally on craigslist for quite cheap, and would be the most beneficial mod of the ones thus far. I will fabricate all hangers, shackle mounts, and shock towers. And will use junk yard parts where acceptable and safe.
-Exocage: An exocage is essentially an exterior roll cage, that doesn't interfere with the interior or any moving parts of the vehicle, to protect the whole vehicle in the event of a rollover or low speed collision with an object on the trail. They're commonly made of chromoly steel tubing.
Useful tools to get along the way
-New box of tools to keep in truck
-Winch tree savers and ****** blocks.
-High Lift Jack
As I said, not all of this will happen soon. Some things later in the list may even take over a year to get around to the design phase. The mods will probably also come slow, and a high possibility of some other cheaper mods being done between.
If you have any suggestions for mods or feedback on my concepts, please let me know! I'm here to learn and share my experiences.
Somewhat recent pictures of the truck:
Last edited by DanielElfert; 05-12-2014 at 08:43 PM.
05-09-2014, 01:09 AM
#2
Winch Project
So first off, I've started on the winch project already. The winch I am using is a 12,000 lb badlands winch from Harbor Freight. Say what you will, but it was $300 and I bought a 2.5 year warranty. It suits my needs. This thing surely doesn't feel cheap. It weighs in at around 86 lbs I believe and feels more sturdy than I could've possibly imagined. I also went ahead and bought a $30 wireless remote. With all the two replacement plans, winch, and remote, it totaled in at $459.97. It wasn't easy forking over 4 weeks of hard work, but I'm happy with my purchase.
Here's a pic of the winch
My plan with the bumper and the winch is to mount the winch on a bracket that will elevate from the frame horns, and the fairlead will go through the bumper. I'd like to add some mounting points for D-Rings as well by welding them to the bumper mounting brackets.
Here's a non-scale sketch of the winch mounting bracket. It may or may not include the triangular piece, depending on the thickness of steel I decide to go with and how high the mounting point is.
The bumper I'm using was a lucky find out of two junkyards. It costed about $38.
I took it home, and used an abrasive pad on a Harbor Freight angle grinder and it took the paint right off. Almost looks chrome
The next step is to cut the hole for the fairlead in the bumper, make a mounting bracket for the fairlead and to reinforce the bumper with some gussets once we cut it.
Here's a pic of the winch
My plan with the bumper and the winch is to mount the winch on a bracket that will elevate from the frame horns, and the fairlead will go through the bumper. I'd like to add some mounting points for D-Rings as well by welding them to the bumper mounting brackets.
Here's a non-scale sketch of the winch mounting bracket. It may or may not include the triangular piece, depending on the thickness of steel I decide to go with and how high the mounting point is.
The bumper I'm using was a lucky find out of two junkyards. It costed about $38.
I took it home, and used an abrasive pad on a Harbor Freight angle grinder and it took the paint right off. Almost looks chrome
The next step is to cut the hole for the fairlead in the bumper, make a mounting bracket for the fairlead and to reinforce the bumper with some gussets once we cut it.
05-09-2014, 11:31 AM
#4
Right now the truck actually does quite well off road, being an open differential 2wd. Last time I went off roading, I made it really far through the mud trail. I eventually got so stuck a tractor had to pull me out. The eventual solid axle swap would convert it to 4x4, but for now I'm satisfied with the 2wd. It's gotten me places I wouldn't think I could.
05-10-2014, 07:51 PM
#5
Winch Project
We cut out the square hole in the bumper today for the fairlead to slide into. Fits pretty nice. The fairlead is set in to where about half the outer rollers are sticking out. This keeps a clean look, yet still will look pretty mean and be fully usable.
After the cut was made
With the fairlead mocked up
Mocked up, view from the back
What the fairlead mounting bracket will look like. Sorry it's so sloppy, it was just thrown on a random piece of cardboard.
So yeah, that's progress on it so far. The next step is to weld in the fairlead bracket, smooth out the edges, and possibly lay down primer the bumper.
I might hold off on the primer though, because I'd still like to add the mount points for the D-rings, which will mount to the winch bracket, and through the bumper.
After the cut was made
With the fairlead mocked up
Mocked up, view from the back
What the fairlead mounting bracket will look like. Sorry it's so sloppy, it was just thrown on a random piece of cardboard.
So yeah, that's progress on it so far. The next step is to weld in the fairlead bracket, smooth out the edges, and possibly lay down primer the bumper.
I might hold off on the primer though, because I'd still like to add the mount points for the D-rings, which will mount to the winch bracket, and through the bumper.
05-19-2014, 12:21 AM
#6
Winch Project
Ok, updates about the winch project. We had the fairlead bracket made by a guy my dad works with. He changed the design slightly, but the with the same concept, just to hold the fairlead in place. Today we welded it in, drilled the bolt holes, and put down a few coats of primer.
After welding the brackets. Forgive the horribly messy welds. Our little 90 AMP flux welder was acting stupid, and extremely inconsistent with it.
Front:
Back:
With the fairlead bolted in
Front:
Back:
After we primed it:
We also finalized measurements and concept for the winch mounting bracket, which we also changed from the original because the mounting point will be lower than I thought. Here's what it will probably take the shape of.
So that's about it for what we've done. I have been moving pretty slow on this due to a combination of school, work, and extracurricular crap.
Next on the list is to have the winch bracket made, paint the bumper completely, find a junkyard valence to cut into, and hopefully mount it fully.
After welding the brackets. Forgive the horribly messy welds. Our little 90 AMP flux welder was acting stupid, and extremely inconsistent with it.
Front:
Back:
With the fairlead bolted in
Front:
Back:
After we primed it:
We also finalized measurements and concept for the winch mounting bracket, which we also changed from the original because the mounting point will be lower than I thought. Here's what it will probably take the shape of.
So that's about it for what we've done. I have been moving pretty slow on this due to a combination of school, work, and extracurricular crap.
Next on the list is to have the winch bracket made, paint the bumper completely, find a junkyard valence to cut into, and hopefully mount it fully.
05-19-2014, 01:42 AM
#7
Looks like a long road to what you want,but it'll be one of a kind! Ever think about swapping in a 5.4 instead of a newer 4.2? I don't think the transmissions are different,should bolt up..
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05-19-2014, 02:00 AM
#8
I even thought about a 12v 5.9 cummins. All mechanical. I've tossed that out though as well because of the sheer weight of the thing would sink the truck, defeating the purpose of a trail rig.
I'm pretty satisfied with the performance the 4.2 has given me so far, even on almost 275,000 miles. I'm sure a rebuild, along with a minor performance mod here and there, would be more than enough to satisfy my needs.
05-19-2014, 02:04 AM
#9
Thanks for the input! And the 4.2 is Essex platform, while 5.4 is Modular. The transmissions, unfortunately, do not bolt up. Also, all new engine mounts and electronics. Nothing impossible. Heck, I saw a thread where a guy swapped in a Ford v10. So it wouldn't be impossible, but would probably end up costing more than what I have a budget for. I've given it lots of thought.
I even thought about a 12v 5.9 cummins. All mechanical. I've tossed that out though as well because of the sheer weight of the thing would sink the truck, defeating the purpose of a trail rig.
I'm pretty satisfied with the performance the 4.2 has given me so far, even on almost 275,000 miles. I'm sure a rebuild, along with a minor performance mod here and there, would be more than enough to satisfy my needs.
I even thought about a 12v 5.9 cummins. All mechanical. I've tossed that out though as well because of the sheer weight of the thing would sink the truck, defeating the purpose of a trail rig.
I'm pretty satisfied with the performance the 4.2 has given me so far, even on almost 275,000 miles. I'm sure a rebuild, along with a minor performance mod here and there, would be more than enough to satisfy my needs.
05-19-2014, 07:42 AM
#10
I'd like to get as much power as I can, I just can't afford a swap like that. I'll probably end up running 35s, maybe up to 37s, whenever the straight axle swap gets done. I guess I'll just have to run some tall gears for it. Possibly 4.10 gears.