Redgrrr
I have a problem with 40s
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Builds Peter's Ultimate Expo Land Cruiser Build Thread
- Thread starter Behemoth60
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- Thread starter
- #303
OK Folks. It's been 2,878 days since I've updated this thread. The dream is still alive. I got a bit side tracked. I decided that my crappy garage was not sufficient workshop in which to build this project. So, I spent 5 years building the ultimate dream workshop. I call it Xanatorium. When that was done, I decided to work on Ziplock first. Builds - Ziplock's revival - https://forum.ih8mud.com/threads/ziplocks-revival.1194261/
But for the last 2,879 sleeps, I've drifted off dreaming of my ultimate Expo build.
Plans have changed dramatically. Having come to terms with my mortality, and realizing that I have more ambitions than lifespan, I've decided to dramatically simplify this build. I am now in posession of a 2005 Ram 2500 chassis, that will form the basis of this build.
-Frame will be the Ram frame, shortened.
-I will use the Ram driveline... 5.9 cummins, G56 manual trans, and probably upgrade to an Atlas 4 spd case.
-I will keep the factory AAM axles (9.25 front, 11.5 rear) and put lockers in them.
-I will upgrade the front 5 link suspension, and completely replace the rear leafs with 5 link air bag kit.
-Body will be that 79 series cab. Custom, auzzy inspired canopy behind that, plus a dog kennel, because I got tricked into having a dog.
I hope that by typing these words, I will commit myself to moving all this kit into the workshop space and re-starting this project in May. of this year. 2023.
In the mean time, here's a pic of the shop I built, with the extensive help of a great many people that are watching. So much gratitude for all their help. I owe you all shop space anytime you want it.
But for the last 2,879 sleeps, I've drifted off dreaming of my ultimate Expo build.
Plans have changed dramatically. Having come to terms with my mortality, and realizing that I have more ambitions than lifespan, I've decided to dramatically simplify this build. I am now in posession of a 2005 Ram 2500 chassis, that will form the basis of this build.
-Frame will be the Ram frame, shortened.
-I will use the Ram driveline... 5.9 cummins, G56 manual trans, and probably upgrade to an Atlas 4 spd case.
-I will keep the factory AAM axles (9.25 front, 11.5 rear) and put lockers in them.
-I will upgrade the front 5 link suspension, and completely replace the rear leafs with 5 link air bag kit.
-Body will be that 79 series cab. Custom, auzzy inspired canopy behind that, plus a dog kennel, because I got tricked into having a dog.
I hope that by typing these words, I will commit myself to moving all this kit into the workshop space and re-starting this project in May. of this year. 2023.
In the mean time, here's a pic of the shop I built, with the extensive help of a great many people that are watching. So much gratitude for all their help. I owe you all shop space anytime you want it.
That's hot, Peter. 
Love the shop Peter!! Pics of Xanatorium were worth the 2,878 day wait! 
Love the shop Peter!! Pics of Xanatorium were worth the 2,878 day wait!
Whoah.
- Thread starter
- #308
OK Friends, another summer has drifted by. I purged my yard of 5 Land Cruiser pojects that I was never going to get to, as well as 2 other cars. I moved the donor 2005 Ram 2500 chassis into my shop, and put on on the hoist where it is in the way of any other projet. I removed the crew cab, and 8' long box. Leaving behind a shockingly long looking canvas of frame rails to build my dream expo truck.
But first , let's re-vist the dream. For inspiration, I reached out to comission Chip Foose to do one of those 'dream' drawings of what the vehicle could look like. Turns out, I can't afford that, so I did my own artwork. This is Plan "A"
As you can clearly see, the plan A is now to stretch the 79 cab by enough to fit a dog, as well as some tools, a cooler, and other sundries one might want inside with you. Then some sort of deck behind that for an australian style camper, or maybe a short camper. This unit from HOME | Optimized Overlanding - https://www.optimizedoverlanding.com/ is litterally everything I've been dreaming for the 'camper'.
But I also really like the OEV Hudson Bay camper made just up the road from me. It would be nice to support a local manufacturer. But not sure I have the budget for this. And having RV"d and Lived under the awning these past 2 summers, I prefer living under the awning vs. trying to live inside the RV space. And indoor space to stand up, get changed, and put on my socks is all I really want form my 'indoor' space. This unit from optimized overlanding delivers on that.
Plan B is to NOT stretch the 79 cab, rathe build a doggy kennel behind the cab to do all the things. Something like this:
That might be easier/faster to build than stretching the 79 cab. Plus, If I ever rolled it, I can just get another 79 cab, and would not have to re-stretch another one. I dunno. Still deciding. I need to to a decision matrix to make the final plan.
Here's where I need your input: Options are:
A) Stretch the 79 cab I already have. Cons: Lots of body work. Pro's: But more leg room for seats, seats can recline, easily conidtioned space for dog, lots of indoor space for stuff.
B) Build a dog kennel behind the 79 Cab: Cons: no extra leg room/seat reclining. Need a passthrough. Pro's. Easier to build. Easier to replace the cab if it get's wrecked. I already have a 79 Cab ready to go.
C) Use a 70 Series cab. Close up the wheel wells, and put a rear panel on the back. Still lots of body work. Can't find a donor 70 series cab anywhere.
D) Shorten a 74 Cab. I found a donor 74 tub. Could shorten that. Would have to deal with the FRP top, but could possibly have a removable top, fold down windshield expo truck! <note: I will NEVER remove the top nor fold down the windshield>
What do you all think? Place your vote here:
But first , let's re-vist the dream. For inspiration, I reached out to comission Chip Foose to do one of those 'dream' drawings of what the vehicle could look like. Turns out, I can't afford that, so I did my own artwork. This is Plan "A"
As you can clearly see, the plan A is now to stretch the 79 cab by enough to fit a dog, as well as some tools, a cooler, and other sundries one might want inside with you. Then some sort of deck behind that for an australian style camper, or maybe a short camper. This unit from HOME | Optimized Overlanding - https://www.optimizedoverlanding.com/ is litterally everything I've been dreaming for the 'camper'.
But I also really like the OEV Hudson Bay camper made just up the road from me. It would be nice to support a local manufacturer. But not sure I have the budget for this. And having RV"d and Lived under the awning these past 2 summers, I prefer living under the awning vs. trying to live inside the RV space. And indoor space to stand up, get changed, and put on my socks is all I really want form my 'indoor' space. This unit from optimized overlanding delivers on that.
Plan B is to NOT stretch the 79 cab, rathe build a doggy kennel behind the cab to do all the things. Something like this:
That might be easier/faster to build than stretching the 79 cab. Plus, If I ever rolled it, I can just get another 79 cab, and would not have to re-stretch another one. I dunno. Still deciding. I need to to a decision matrix to make the final plan.
Here's where I need your input: Options are:
A) Stretch the 79 cab I already have. Cons: Lots of body work. Pro's: But more leg room for seats, seats can recline, easily conidtioned space for dog, lots of indoor space for stuff.
B) Build a dog kennel behind the 79 Cab: Cons: no extra leg room/seat reclining. Need a passthrough. Pro's. Easier to build. Easier to replace the cab if it get's wrecked. I already have a 79 Cab ready to go.
C) Use a 70 Series cab. Close up the wheel wells, and put a rear panel on the back. Still lots of body work. Can't find a donor 70 series cab anywhere.
D) Shorten a 74 Cab. I found a donor 74 tub. Could shorten that. Would have to deal with the FRP top, but could possibly have a removable top, fold down windshield expo truck! <note: I will NEVER remove the top nor fold down the windshield>
What do you all think? Place your vote here:
- Thread starter
- #309
But before I can put cab's and campers on, I have some essential drivetrain/chassis mods to attend to, even before I decide on how much I need to shorten the frame..
This donor chassis has the 5.9HO Cummins, G56 6 speed manual (the one with the 6.5:1 1st gear), and an NP271HD Transfer Case. Dodge's 5 link coil suspension up front with the AAM9.25 axle, and a all the leaf sprigns on the giant AAM11.5 rear axle. It comes with 3.7 gears. I am ditching the leaf springs for a link suspension, and doing air bag springs all around.
Of criticla importance is the wheel/tires. I already have them... Trail Ready DOT double beadlocks, with Michelin 12.50R20 XL's.
Now, I know what you're thinking. Those directional XL's are noisy on the road, and only 40" tall, and ridiculously wide at 12.5". Why not get the tantalizing 11.00R20 XZL's that are non directional, quieter, 43" tall, and 6% narrower? Well, I don't aleady own them. The 12.50's are pretty close in size, and when I wear them out, I will definately get the 11's.
So, I am on a spending spree... ARB Locker, Detroit Locker, Air bags, Trple Bypass shocks, diff shave kit and HD diff covers and link ends for the rear suspension. You should see an up tick in the economy coming soon.
This donor chassis has the 5.9HO Cummins, G56 6 speed manual (the one with the 6.5:1 1st gear), and an NP271HD Transfer Case. Dodge's 5 link coil suspension up front with the AAM9.25 axle, and a all the leaf sprigns on the giant AAM11.5 rear axle. It comes with 3.7 gears. I am ditching the leaf springs for a link suspension, and doing air bag springs all around.
Of criticla importance is the wheel/tires. I already have them... Trail Ready DOT double beadlocks, with Michelin 12.50R20 XL's.
Now, I know what you're thinking. Those directional XL's are noisy on the road, and only 40" tall, and ridiculously wide at 12.5". Why not get the tantalizing 11.00R20 XZL's that are non directional, quieter, 43" tall, and 6% narrower? Well, I don't aleady own them. The 12.50's are pretty close in size, and when I wear them out, I will definately get the 11's.
So, I am on a spending spree... ARB Locker, Detroit Locker, Air bags, Trple Bypass shocks, diff shave kit and HD diff covers and link ends for the rear suspension. You should see an up tick in the economy coming soon.
I vote for plan A, for leg room and seat reclining (your comfort) and dog habitat (their comfort). There is no way you are gonna have that dog in an outside space, so just build the platform and enough space for a dog bed. storage underneath. maybe 2 or 3 feet?
lowenbrau
SILVER Star
For inspiration. ( I know spare tire location is a challenge.)
- Thread starter
- #312
Another 533 days have passed since the last update.
Looking back, I first talked about this build in 2008. So.. I've only beein working on this for.... 17 years.
But, I indeed, HAVE been working on this project. Plan B is underway. Shortened 2005 Ram 2500 frame. 79 series cab. a 'kennel' of some sort, with a flat deck behind that. Air bags, triple bypass shocks, links everywhere. 5.9 common rail Cummins - 6 speed G56, NWF doubler, NP205 transfer case. Stock axles, with air lockers, and 11.00R20 Michelin tires (43" tall). That's the plan. Some random progress pics from the past 18 months....
Looking back, I first talked about this build in 2008. So.. I've only beein working on this for.... 17 years.
But, I indeed, HAVE been working on this project. Plan B is underway. Shortened 2005 Ram 2500 frame. 79 series cab. a 'kennel' of some sort, with a flat deck behind that. Air bags, triple bypass shocks, links everywhere. 5.9 common rail Cummins - 6 speed G56, NWF doubler, NP205 transfer case. Stock axles, with air lockers, and 11.00R20 Michelin tires (43" tall). That's the plan. Some random progress pics from the past 18 months....
- Thread starter
- #313
- Thread starter
- #314
Hanna Quality
Supporting Vendor
stoked to see you back on your build!
So far do you like using the truck frame vs custom square tube? Is the cab and suspension fitting without issue vs where the frame has bends and the frame width?
Any downfalls using the stock axles? Lockers and gear ratios?
I here dead lines like making it to Rubithon 2025 are the best motivators
So far do you like using the truck frame vs custom square tube? Is the cab and suspension fitting without issue vs where the frame has bends and the frame width?
Any downfalls using the stock axles? Lockers and gear ratios?
I here dead lines like making it to Rubithon 2025 are the best motivators
- Thread starter
- #316
factory frame vs. custom Square tube: Much
Factory frame is nice.. A big upgrade, actually. it has the right bends in the right places, and lots of things are easier because of that. Especially the whole steering, panhard, sway bar setup. I am keeping all that. I also think it is just stronger and lighter... higher tensile steel, hydroformed, and such. All good. But, there were still lots of changes.
But I am making up for the 3.7's and 43" tires by getting rid of giant factory chain NP271, and replacing that with a NWF Eco-Box (re-using the planetary gearset from the 271) into an 32 spline Ford NP205 with the 'Titan' upgrade input shaft from NWF. This double low range will make up for the 3.7's for off-roading. And believe it or not, the NP205 with 'Integrated' EcoBox from NWF is the same overall length as the factory NP271. This means that even with moving the engine back, and adding a doubler, I can still fit that driveline in front of the middle factory cross member. Lots of room under the cab, so I was able to set it all so it will have a completely 'flat belly' under the frame rails.
Factory axles have limited locker options, but ARB's are available. That rear AAM 11.5 diff is crazy large. The Pinion gear is as big as the entire diff from an 8" toyota diff (not really, but it's fun to say) Ballistic Fab makes a Shave kit for the AAM 11.5, so of course, I did the shave on the rear axle.
I kept the factory front lower link mounts on the front axle, and the factory front panhard. Everything else is custom. "3 Link" front and rear, using 12" travel air bags, and 12" Triple Bypass Radflo shocks. For fun, I am using 'The Kong' dog chew toys for bump stops. Seriously!
Front axles are mostly ffabricated. Ready for welding. That' what I am working on now.
Sadly, probably no Rubicon, or any US trips for that matter, for a while.
Factory frame is nice.. A big upgrade, actually. it has the right bends in the right places, and lots of things are easier because of that. Especially the whole steering, panhard, sway bar setup. I am keeping all that. I also think it is just stronger and lighter... higher tensile steel, hydroformed, and such. All good. But, there were still lots of changes.
- I took 2 feet out of the middle of the frame, under the cab.
- I am keeping the front axle in the same place, to re-use the steering box and panhard mounts and such,
- but with using the big 43" tires, I had to move the cab back from factory location to clear the tires.
- That led to moving the engine back 6" as well to tuck up under the firewall
- But then the accesories would not fit between the skinny part of the frame, so I had to shimmy the engine to the left a bit more than factory, but since I was doing custom mounts, I was able to make everything fit.
- custom body mounts of course . I was place the cab snugly around the enging with the shift poking through the floor at about factory ish location. The body mounts on the 79 cab are just wide enough to clear the frame. So far, i have not needed to make any mods to the 79 cab.
After MUCH calculation and ruminations, I decided to keep the stock 3.7 gears, which will give me nice an low rpm's on the highway with the big tires. The biggest thing I will ever tow is my boat at 3500 lbs, so I don't think I need any lower gears on road.
But I am making up for the 3.7's and 43" tires by getting rid of giant factory chain NP271, and replacing that with a NWF Eco-Box (re-using the planetary gearset from the 271) into an 32 spline Ford NP205 with the 'Titan' upgrade input shaft from NWF. This double low range will make up for the 3.7's for off-roading. And believe it or not, the NP205 with 'Integrated' EcoBox from NWF is the same overall length as the factory NP271. This means that even with moving the engine back, and adding a doubler, I can still fit that driveline in front of the middle factory cross member. Lots of room under the cab, so I was able to set it all so it will have a completely 'flat belly' under the frame rails.
Factory axles have limited locker options, but ARB's are available. That rear AAM 11.5 diff is crazy large. The Pinion gear is as big as the entire diff from an 8" toyota diff (not really, but it's fun to say) Ballistic Fab makes a Shave kit for the AAM 11.5, so of course, I did the shave on the rear axle.
I kept the factory front lower link mounts on the front axle, and the factory front panhard. Everything else is custom. "3 Link" front and rear, using 12" travel air bags, and 12" Triple Bypass Radflo shocks. For fun, I am using 'The Kong' dog chew toys for bump stops. Seriously!
Front axles are mostly ffabricated. Ready for welding. That' what I am working on now.
Goal is to 'test drive' it before next winter. Focusing on 'minimum viable build' for this summer. Then next winter, take it back apart and paint it up nice. Build/Buy some kind of camping box for it at that time too. Probably just a simple flat deck for this summer.I here dead lines like making it to Rubithon 2025 are the best motivators
Sadly, probably no Rubicon, or any US trips for that matter, for a while.
