Truggy Build 3.0

94Dodge Truggy · 11-15-2017, 04:14 PM

Building a truggy from a 2004 Dodge Ram 1500.

Picked this up from Cincy Thouroubred Harley Davidson. Was a parts hauler till it got side swiped on the highway.
Parts that I will be keeping on the truck are part of the front end, most of the frame, motor, trans and cab. Sold most of what I am not using to help the funds. Still wondering if the cab should go or not.

Here is what I am currently thinking of using for this build.

97 Dodge dually Dana 60 front 4.10 gears welded (looking to upgrade shafts)

2004 GMC 2500 14 bolt 10.5 ring gear rear. Posi that I need to lock in some fashion.

Full hydro from PSC ? or homebrew

NP241 Rubicon t-case 4 to 1

1350 driveshafts. Have 2 fronts from JK builds that I will build up

42" Irok Stickies with Stazworks dual beadlocks (thanks Scott A)

Warn 8274 that I have had for quite a while

116" wheelbase possibly and shooting for under 5000 lbs.

4 link front with track bar, 3 link rear with track bar, 4" JK springs, looking into heim joint brands

94Dodge Truggy · 11-15-2017, 04:21 PM

Stripped the 1/2 ton bits away from the chassis. Lightening mode now.

94Dodge Truggy · 11-16-2017, 01:21 PM

Moved to the welding / fab area. Still shaving weight.

jeepmanjeff · 11-17-2017, 12:10 PM

NICE! Back on the trails soon?

monkeystrong · 11-17-2017, 12:48 PM

Too cool!

Runoveru2 · 11-18-2017, 11:32 AM

This thing will be a beast

93 Krawler · 11-18-2017, 08:37 PM

Better take it easy on that 241. I've broken the case around the front output 4 times on mine. Decided to take a different route on the s10.

Sent from my SM-G930V using Tapatalk

bbtank45 · 11-20-2017, 10:29 AM

Quote:

Originally Posted by 93 Krawler

Better take it easy on that 241. I've broken the case around the front output 4 times on mine. Decided to take a different route on the s10.

Sent from my SM-G930V using Tapatalk

Glad to hear you speak of the s10 again....any updates?

93 Krawler · 11-20-2017, 07:19 PM

I'll be ordering tube soon and getting busy on it. Been finishing up some stuff so i can get it done. Had to beef up the rzr since the truck will be down for a while. end hijack

94Dodge Truggy · 11-22-2017, 08:02 AM

Shaving a 14 bolt currently, adding a spool, new brake hardware and truss.

jeepmanjeff · 11-22-2017, 06:34 PM

hmmm...want to do another one? Call me...5132507941!

94Dodge Truggy · 11-27-2017, 08:02 AM

Quote:

Originally Posted by jeepmanjeff

hmmm...want to do another one? Call me...5132507941!

Not really! It is not a major shave. Ring gear is still stock.

94Dodge Truggy · 11-27-2017, 08:03 AM

Quote:

Originally Posted by 93 Krawler

Better take it easy on that 241. I've broken the case around the front output 4 times on mine. Decided to take a different route on the s10.

Sent from my SM-G930V using Tapatalk

Was the rear a fixed yoke output? I have never seen a 241OR destroyed on the trail behind big hp.

93 Krawler · 11-27-2017, 08:39 AM

I never had a problem with the rear, it was always the front output that cracked the case. I could still drive it after the front broke. Two of the four breaks were front drive shaft related. I broke one going up little Jagger , and the last one I'm not sure why it broke. I was on the waterfall at Harlan. These are 241 C, I know the one you're referring to is stronger but is the case stronger in that area. My transfer case I can get for $85 at any junk yards, but yours is a lot more expensive and harder to find.

Sent from my SM-G930V using Tapatalk

94Dodge Truggy · 11-28-2017, 08:05 AM

The front cover area is different in design and just the front case cover can be bought for 110.00 separately. Crossing my fingers.

jeepmanjeff · 11-28-2017, 09:30 AM

hey Kevin. when you order tubing let me know. I will order some as well with you so we can get a better discount. I get a Military discount at Ackerman as well.

Drivermod · 11-29-2017, 02:55 PM

Quote:

Originally Posted by 94Dodge Truggy

The front cover area is different in design and just the front case cover can be bought for 110.00 separately. Crossing my fingers.

I have a Rubicon case that came out of my 05 LJ. Both halves of the case around the front output are cracked due to my front driveshaft ejecting at highway speed. The rest of its fine. I kept it for spare parts but sold the LJ. You are welcome to it if you think there is anything you can use off of it.

94Dodge Truggy · 11-30-2017, 06:33 AM

Quote:

Originally Posted by Drivermod

I have a Rubicon case that came out of my 05 LJ. Both halves of the case around the front output are cracked due to my front driveshaft ejecting at highway speed. The rest of its fine. I kept it for spare parts but sold the LJ. You are welcome to it if you think there is anything you can use off of it.

That's a deal! It will at least be good for parts. Will you be at the next meeting?

WrenchMonkey · 11-30-2017, 02:32 PM

Quote:

Originally Posted by 94Dodge Truggy

Will you be at the next meeting?

(FYI, no December meeting, next isn't until January 11th...)

Drivermod · 11-30-2017, 05:18 PM

Quote:

Originally Posted by 94Dodge Truggy

That's a deal! It will at least be good for parts. Will you be at the next meeting?

Probably not. Raising 7 kids I don't have much time for club stuff. I live in Union. Give me a call if you want to come get it. (859)786-9785

94Dodge Truggy · 12-18-2017, 07:39 AM

Mocking up suspension and links. 86" wide x 126" wheelbase. Machined a custom overdrive power steering pulley. Hit the mark!

jeepmanjeff · 12-18-2017, 09:02 AM

looking good!

monkeystrong · 12-20-2017, 08:20 PM

Quote:

Originally Posted by 94Dodge Truggy

Mocking up suspension and links. 86" wide x 126" wheelbase. Machined a custom overdrive power steering pulley. Hit the mark!

This thing is going to be awesome!

jeepmanjeff · 01-03-2018, 03:40 PM

Stopped by today and it is really looking good!

94Dodge Truggy · 02-27-2018, 06:47 AM

Suspension is tacked in and front bumper is being built.

11-15-2017, 04:14 PM	#1
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Truggy Build 3.0 Building a truggy from a 2004 Dodge Ram 1500. Picked this up from Cincy Thouroubred Harley Davidson. Was a parts hauler till it got side swiped on the highway. Parts that I will be keeping on the truck are part of the front end, most of the frame, motor, trans and cab. Sold most of what I am not using to help the funds. Still wondering if the cab should go or not. Here is what I am currently thinking of using for this build. 97 Dodge dually Dana 60 front 4.10 gears welded (looking to upgrade shafts) 2004 GMC 2500 14 bolt 10.5 ring gear rear. Posi that I need to lock in some fashion. Full hydro from PSC ? or homebrew NP241 Rubicon t-case 4 to 1 1350 driveshafts. Have 2 fronts from JK builds that I will build up 42" Irok Stickies with Stazworks dual beadlocks (thanks Scott A) Warn 8274 that I have had for quite a while 116" wheelbase possibly and shooting for under 5000 lbs. 4 link front with track bar, 3 link rear with track bar, 4" JK springs, looking into heim joint brands Attached Thumbnails __________________ Last edited by 94Dodge Truggy; 11-15-2017 at 04:19 PM.

11-15-2017, 04:21 PM	#2
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Stripped the 1/2 ton bits away from the chassis. Lightening mode now. Attached Thumbnails __________________

11-16-2017, 01:21 PM	#3
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Moved to the welding / fab area. Still shaving weight. Attached Thumbnails __________________

11-17-2017, 12:10 PM	#4
jeepmanjeff Ah Unz ze President! - CORE Member - - Moderator - Join Date: Jan 2007 Location: Fairfield Ohio Posts: 588 Images: 343	NICE! Back on the trails soon? __________________ Keep them on all 4's

11-18-2017, 11:32 AM	#6
Runoveru2 Adrenaline Junkie - CORE Member - - Moderator - Join Date: Jun 2011 Location: Hamilton, Ohio Posts: 702 Images: 168	This thing will be a beast __________________ No need for a Winch...You just have to make it !!

11-17-2017, 12:48 PM	#5
monkeystrong Señor Monkey Join Date: May 2012 Location: Georgetown, Ohio Posts: 185	Too cool!

11-18-2017, 08:37 PM	#7
93 Krawler >>>PMC<<< - CORE Member - - Administrator - Join Date: Sep 2010 Location: Ross, OH Posts: 2,069 Images: 1268	Better take it easy on that 241. I've broken the case around the front output 4 times on mine. Decided to take a different route on the s10. Sent from my SM-G930V using Tapatalk

11-20-2017, 07:19 PM	#9
93 Krawler >>>PMC<<< - CORE Member - - Administrator - Join Date: Sep 2010 Location: Ross, OH Posts: 2,069 Images: 1268	I'll be ordering tube soon and getting busy on it. Been finishing up some stuff so i can get it done. Had to beef up the rzr since the truck will be down for a while. end hijack

11-22-2017, 08:02 AM	#10
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Shaving a 14 bolt currently, adding a spool, new brake hardware and truss. __________________

11-22-2017, 06:34 PM	#11
jeepmanjeff Ah Unz ze President! - CORE Member - - Moderator - Join Date: Jan 2007 Location: Fairfield Ohio Posts: 588 Images: 343	hmmm...want to do another one? Call me...5132507941! __________________ Keep them on all 4's

11-27-2017, 08:39 AM	#14
93 Krawler >>>PMC<<< - CORE Member - - Administrator - Join Date: Sep 2010 Location: Ross, OH Posts: 2,069 Images: 1268	I never had a problem with the rear, it was always the front output that cracked the case. I could still drive it after the front broke. Two of the four breaks were front drive shaft related. I broke one going up little Jagger , and the last one I'm not sure why it broke. I was on the waterfall at Harlan. These are 241 C, I know the one you're referring to is stronger but is the case stronger in that area. My transfer case I can get for $85 at any junk yards, but yours is a lot more expensive and harder to find. Sent from my SM-G930V using Tapatalk

11-28-2017, 08:05 AM	#15
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	The front cover area is different in design and just the front case cover can be bought for 110.00 separately. Crossing my fingers. __________________

11-28-2017, 09:30 AM	#16
jeepmanjeff Ah Unz ze President! - CORE Member - - Moderator - Join Date: Jan 2007 Location: Fairfield Ohio Posts: 588 Images: 343	hey Kevin. when you order tubing let me know. I will order some as well with you so we can get a better discount. I get a Military discount at Ackerman as well. __________________ Keep them on all 4's

12-18-2017, 07:39 AM	#21
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Mocking up suspension and links. 86" wide x 126" wheelbase. Machined a custom overdrive power steering pulley. Hit the mark! Attached Thumbnails __________________

12-18-2017, 09:02 AM	#22
jeepmanjeff Ah Unz ze President! - CORE Member - - Moderator - Join Date: Jan 2007 Location: Fairfield Ohio Posts: 588 Images: 343	looking good! __________________ Keep them on all 4's

01-03-2018, 03:40 PM	#24
jeepmanjeff Ah Unz ze President! - CORE Member - - Moderator - Join Date: Jan 2007 Location: Fairfield Ohio Posts: 588 Images: 343	Stopped by today and it is really looking good! __________________ Keep them on all 4's

02-27-2018, 06:47 AM	#25
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Suspension is tacked in and front bumper is being built. Attached Thumbnails __________________