I'm a Mechanical Engineering major attending Penn State. We have to do a senior design project in cooroperation with a company. My group and I thought we might try to make an SAS kit for the rangers (since there really isn't one out there).

I have a few questions for you guys.

What is the demand for an SAS kit for the rangers?

Would you buy an SAS kit? if so how much would you pay?

The point of this would to be to make a kit that is easily installed. Not nessasarily bolt in, but everything would already be taken care of and in the kit. this would include:
-steering
-bracketry
-springs
-track bar
-hardware
-brake lines

the kit will most likely be leaf springs, for simplicity.

also, what companies would you guys recomend inquiring about this? Superlift? Fabtech? Rough Country? input on these comanys would be appriciated.

thanks for your imput and cooroperation.

-Kyle

i wouldn't waste my time trying to get those big companies to help. i would start with the smaller (local if possible) companies.

also don't spend forever trying to make the kit work for every truck and axle combo out there. pick one model year, and one or two axles and concentrate on those. it'll be harder to sell but you'll have a way better chance of finishing the project.

If your gunna go leafs I would go with one of the toyota spring companies IE: marlin, TG, APOR, etc.

I think there would be a demand for a kit like that just not a very big one. IMO you would probly be catering to the show truck crowd and some wheelers every now and again.

you would also have to make the kit capable of being adaptable to a slew of different axles like Dana 30,44,60 just to name a few common ones.

I believe the folks at www.bbpfab.com have several Ranger SAS kits in the works already. You may want to get in touch with them and see what you might be able to collaborate on.

I know jeffs bronco graveyard used to sell the fabratech solid axle kit for the rangers. Most people that are gonna do the sas are gonna fab it the way they want.

I've heard something that James Duff was also gearing up to release a SAS kit for '83-'97 TTB trucks.

What I'd like to see is a kit for the '98up IFS Rangers. Coil kits will be much more popular than leaf kits, regardless of how good or bad leafs are.

I'd probably say around $1000-1500 would be a fair price range for such a kit, not including the axle (a new front driveshaft & steering box would need to be a part of the kit).

I know jeffs bronco graveyard used to sell the fabratech solid axle kit for the rangers. Most people that are gonna do the sas are gonna fab it the way they want.

That kit is total shit, you have to use TTB coils which provide zero flex in that application. You are better off gathering parts like radius arms & mounts and coil buckets off any 70's ford coil sprung trucks and use EB coils. This set up will outperform the Fabritech kit at a fraction of the cost.

I've heard something that James Duff was also gearing up to release a SAS kit for '83-'97 TTB trucks....

True, they list extended radius arms in their latest catalog for 83-97 SAS on a Ranger. They are probably working on the other bracketry as well.

I see a Kit for 98+ trucks being more in demand then that of a 97-older kit. the 97-older trucks are pretty easy to setup with a ford radius arm system so I think a 98+ system being a real hole in the market.

On a side note Im in the same boat as you, as I have my senior design project this summer and Ive been coming up with ideas like a doubler kit that will support a rear Tcase other then the Ranger 1354, like a Dana 300 or Something along those lines.

the parts are out there to do it.... just collect em and you'l have your "kit"...

the parts are out there to do it.... just collect em and you'l have your "kit"...

Im pretty sure hes talking about ready welded hangers and jigs a stuff so that you just line everything up and weld or bolt it on. There are no "parts" out there right now to do that to a ranger. Yea you can buy steel or try and adapt another companies parts to your truck, but hes talking about designing a ground up kit from scratch so that it is tailor made to the truck, not a bunch of parts he went around and bought.

so what would you need thats special to rangers...???

what type of suspension would you run...?

links? 3 or 4 ?

radius arms ? factory ford or Duff or Cage or Wild Horses..??

what axle would you require...???

anything less than a D44 would be a waste of time


lots of variables to figure out...

on another board i am on they just had a review of a bolt in sas kit for rangers and bronco II's

so what would you need thats special to rangers...???

what type of suspension would you run...?

links? 3 or 4 ?

radius arms ? factory ford or Duff or Cage or Wild Horses..??

what axle would you require...???

anything less than a D44 would be a waste of time


lots of variables to figure out...

He mentioned leafs.

He wants it to be a kit that would be specific to the ranger frame, not just a random bunch of hangers you have to fiddle with to get to fit. Im sure each bracket and hanger would be specficly designed to fit a rangers frame.

on another board i am on they just had a review of a bolt in sas kit for rangers and bronco II's

Its prolly the fabritech kit.

He mentioned leafs.

He wants it to be a kit that would be specific to the ranger frame, not just a random bunch of hangers you have to fiddle with to get to fit. Im sure each bracket and hanger would be specficly designed to fit a rangers frame.

I understand this... but you gotta start planning it somewhere....

point is... theres so many different ways to do it already, whats gonna make it standout...???

for instance:

http://www.ballisticfabrication.com/assets/images/3framewedge1.jpg

18.99 each for 3" joints x 2 = 37.98 ... weld to frame (after boxing it)

http://www.ballisticfabrication.com/assets/images/flexjoint/3-inch-flex-joint.jpg

61.99 each x 2 = 123.98 (not fan of heims on links)

http://secure.yisi.net/cageoffroad/images/F2F1_100.jpg

725.00 a set ... you could save $$ and use the heims if you wanted.


coil springs from 129.99 - 159.99 .. http://www.wildhorses4x4.com/category/coils

shocks of your choice

then you still hafta build a correct type steering..... it'll be different depending on what type axle you use...

if it's gonna be just a leaf setup... I don't see the point...

I understand this... but you gotta start planning it somewhere....

point is... theres so many different ways to do it already, whats gonna make it standout...???

for instance:

http://www.ballisticfabrication.com/assets/images/3framewedge1.jpg

18.99 each for 3" joints x 2 = 37.98 ... weld to frame (after boxing it)

http://www.ballisticfabrication.com/assets/images/flexjoint/3-inch-flex-joint.jpg

61.99 each x 2 = 123.98 (not fan of heims on links)

http://secure.yisi.net/cageoffroad/images/F2F1_100.jpg

725.00 a set ... you could save $$ and use the heims if you wanted.


coil springs from 129.99 - 159.99 .. http://www.wildhorses4x4.com/category/coils

shocks of your choice

then you still hafta build a correct type steering..... it'll be different depending on what type axle you use...

if it's gonna be just a leaf setup... I don't see the point...


You seem to be missing the point. Think of it like the Trail-gear IFS elminator for toyotas. It would be made to use a specific axle and made specificly for a ranger, not a jumble of parts like you listed above.

http://www.trail-gear.com/images/sas-600.jpg

This kit is made specificly to use a 79-85 yota axle comes with specific parts that are tailored to the toyotas frame.

Just cause you dont want to run leafs doenst mean everyone doesnt also. They are still popular and would be a great upgrade from the crappy front IFS of the 98+ rangers.

You seem to be missing the point. Think of it like the Trail-gear IFS elminator for toyotas. It would be made to use a specific axle and made specificly for a ranger, not a jumble of parts like you listed above.

http://www.trail-gear.com/images/sas-600.jpg

This kit is made specificly to use a 79-85 yota axle comes with specific parts that are tailored to the toyotas frame.

Just cause you dont want to run leafs doenst mean everyone doesnt also. They are still popular and would be a great upgrade from the crappy front IFS of the 98+ rangers.

thats what I was thinkin... now heres the next question....

what axle would you build it for...???

On a side note Im in the same boat as you, as I have my senior design project this summer and Ive been coming up with ideas like a doubler kit that will support a rear Tcase other then the Ranger 1354, like a Dana 300 or Something along those lines.


D+D machine supposidly already made one to adapt a 1354 to a d300. My friend was supposed to get one but after months of waiting he sold the truck since it was nothing but a paper weight at that point. Last I heard the guy that bought the rig was still waiting for the doubler to get it back together:shaking:


sureshot make sure its a nice easy to work with and simple. I've done a few SAS's on toyota's and helped do 2 Ranger SAS's. We did my SAS on my toy in a day. Drove it in the shop and pulled it out later to go get food. Its layed out real simple though.

D+D machine supposidly already made one to adapt a 1354 to a d300. My friend was supposed to get one but after months of waiting he sold the truck since it was nothing but a paper weight at that point. Last I heard the guy that bought the rig was still waiting for the doubler to get it back together:shaking:


sureshot make sure its a nice easy to work with and simple. I've done a few SAS's on toyota's and helped do 2 Ranger SAS's. We did my SAS on my toy in a day. Drove it in the shop and pulled it out later to go get food. Its layed out real simple though.

we're not talking 'yota's, we're talking rangers.... there's difference.... it's easy to drop a factory yota straight axle in but where you gonna find a factory ranger straight axle...??? there aint one..

to get the same bolt pattern as the rear, your gonna hafta use a D30 from a Jeep... to get a D44 with a the same BP, you'll hafta use a Rubicon axle ..... either way, they will be setup for coils unless you can find a YJ D30 and then you'll hafta worry about doin an SOA..... unless you get a 94-95 then you'll have two piece shafts... so it makes sense to get a very easy to find and very abundant XJ axle...... there agin... setup for coils...

you could use early bronco axles.... but why...????

theres a reason people swap in BOTH axles at the same time....


then theres the weak ass ranger rear... you might as well swap in a 'sploder 8.8 while your at it... now your back to swapping BOTH axles ... so what are you gonna get a matching set out of... HP44 / 9".... good choice, but does everybody want full width....???

waggy D44's...???? 6 bolt pattern means new wheels...


all I'm saying is, there's more to think about than just developing an sas kit.... there's gonna hafta be some type of guidelines...


for simplicity... build a bolt on crossmember that you can use with extended radius arms.... a DOM tracbar w/new frame mount .... steering options for EB axles or full width D44/9" .....

otherwise... keep it simple and build a Clayton style radius arm to work with the same crossmember and a D30 or D44 from an XJ or TJ....




oh.... and I know how to sas a rig.... :flipoff2:

Id make it for a waggy D44 as that is one of the more popular axles that gets used. I have a waggy under the front of my truck its just not connected to anything yet. Lug patterns is a mute point as they make adapters to go from 5x4.5 to 6x5.5 and you could use those on the rear. If you swap in a Explorer rear you can have alloy shafts made with the 6x5.5 pattern also.

D+D machine supposidly already made one to adapt a 1354 to a d300. My friend was supposed to get one but after months of waiting he sold the truck since it was nothing but a paper weight at that point. Last I heard the guy that bought the rig was still waiting for the doubler to get it back together:shaking:


sureshot make sure its a nice easy to work with and simple. I've done a few SAS's on toyota's and helped do 2 Ranger SAS's. We did my SAS on my toy in a day. Drove it in the shop and pulled it out later to go get food. Its layed out real simple though.

Yea I know DD "made" one, but I have some other ideas that would make it unique and it prolly wouldnt use a D300, prolly something thats easyer and cheaper to get.

Id make it for a waggy D44 as that is one of the more popular axles that gets used. I have a waggy under the front of my truck its just not connected to anything yet. Lug patterns is a mute point as they make adapters to go from 5x4.5 to 6x5.5 and you could use those on the rear. If you swap in a Explorer rear you can have alloy shafts made with the 6x5.5 pattern also.

I can see that.... but how many waggy axles are left out there...???? remember, we're talking mass production....


what about brakes for the rear if you get custom shafts...??? thats just more money....

if you can find some 5 lug to 6 lug adapters that will keep the wms correct... please post them up...

what kinda price range are you looking to get for this custom setup...????

waggy axles are popular but its easier to find a D44/9" combo, thats also a pretty popular setup, thats what im planning on using when i get around to a SAS project, i say go for it, i would look into buying the kit if it was well crafted and for a decent price

we're not talking 'yota's, we're talking rangers.... there's difference.... it's easy to drop a factory yota straight axle in but where you gonna find a factory ranger straight axle...??? there aint one..


Point was keeping it simple as possible makes it easier to market. If its a PITA to install why not just make it yourself at that point?

I dont know about where you guys are but here Waggy 44's are a PITA to find and get sucked up fast. They are desirable for alot of different builds.

I think your a few years late. 5 years ago you would have had a real market for this but nowadays evryone has already figured out how to sas the first gen rangers and no one wants to put leafs on a 2nd or 3rd gen ranger.

If you came up with some sort of coilover kit you would get more attention from the serious guys but that has already been figured out too. Look at Ali's ranger from the petersons magazine. He sasd a 2nd gen with an off the shelf almost all bolt on kit that used coilovers.

Finally, the thing that makes the toyota kits so poular is that they utiize a specific axle. Everyone that sas's a ranger uses a different axle. Yes some axles are more popular than others, but this factor would still eliminate many of your target buyers

Duff's should be releasing one soon...A friend of mine...Brett, is a fabricator there and i have seen his broncoII with the Duff's kit on it, extended radius arms and all...it looks sweet! it is a simple design based loosely on the EB/f-series 3 link...contains alot of the engineering already out there, such as the bolt on track bar bracket which bolts on the outside of the frame rail usig the steering box bolts...ect. anyone interested give Duff's a call Tom, Brett, Susie and the whole crew are awesome to deal with! tell them Pottsie sent ya!

[QUOTE=Gregg_O;8186734]I think your a few years late. 5 years ago you would have had a real market for this but nowadays evryone has already figured out how to sas the first gen rangers

i would disagree...there are ALOT of 1 gen RBV's out there, they are usually available on the cheap. Duff's have built an entire company around the EB. i see the same potential for the RBV's that EB's had...potential for performance and growth in the aftermarket, and a resurgence in popularity....then again i am prejudiced...i am a BII man! :smokin:

Point was keeping it simple as possible makes it easier to market. If its a PITA to install why not just make it yourself at that point?

EXACTLY...

i stopped by to have lunch with tom broberg of duffs on monday, he says the kit is almost done...as i said it is loosly based on the ford 3 link...the last hurdle designing a track bar mount for the front end which can be applied to whichever axle the customer will be using...eb 44, heep 30, full size 44 ect. personally i would have made the application to a specific axle, but they want to offer as many options to the customer they can. they have lot of new stuff on their plate right now...they have a new 4 link coil spring conversion for the EB, as well as an SAS for the TTB full size fords (SWEET!). he says he expects release by mid summer on the rbv stuff. as i said before...give them a call!

in my opinion, a tranny crossmember/link mount could be very useful like the belly pans for TJs and XJs. something that would also clear the driveshaft.