The truck suspension needs new bushings all around. Rather than replace the bushings in the front, we chose to replace the upper and lower control arms. For the suspension the total replacement, addition, and upgrade part list is:
Upper control arms (replace for new bushings)
Coil springs (slight load upgrade)
Lower control arm (replace for new bushings)
Front sway bar (replace for new bushings)
Front shocks (replace)
Rear flat spring bushings (replace)
Rear coil over shocks (upgrade)
Rear sway bar (addition; normally only in 4×4 models)
Helper springs (addition)
Note: Initially we thought we would airbag the suspension to increase it’s load capacity. After considering the price of buying and maintaining airbags, we decided to try the aforementioned upgrades first.
Our premise in building this mutant vehicle is this to take the base vehicle, remove as much as possible to get its weight down, upgrade the suspension to expand its load capacity as high as possible without “lifting” the vehicle, and then create the mutation.
In one day we removed the seats, windshield, cab, air conditioning, dashboard, and steering column.
On July 5, 2018 a team of five of us got together and decided to build a mutant vehicle. Initial requirement was that the base vehicle be towable on the existing tandem trailer that Jackhammr owns.
Vehicles considered were a Toyota pickup, Tacoma, 4Runner, Chevrolet S-10, Ford Ranger, and Jeep Cherokee.
After some debate about what makes a good small truck base to carry 10 – 12 people at 5 MPH, the following requirements were added:
2 x 4, a four wheel drive vehicle is more parts and more maintenance and does not provide enough extra low end torque to make the extra maintenance worthwhile
Midsize pickup truck, a midsize truck provides a towable yet load-bearing base to work with. An equivalent SUV could be acceptable, however a pickup truck body will be easier to separate and mutate.
Xtra cab, any extra cab, double cab or long bed options will provide a longer wheelbase to work with. The Ford Ranger extra cab wheelbase goes up to 125.6”.
Maximum 200,000 miles, the expected life of most of the small to midsize truck engines is about 300,000 miles. A vehicle having less than 200,000 miles would be ideal.
Automatic transmission, given that most of the usage will be at 5 – 20 MPH with frequent stops at a high load capacity, an automatic transmission will be easier to drive and will not be a risk of burning up a clutch due to usage and load.
We also determined the initial upgrades we would need to make:
Air Bag Suspension, add air bag suspension to increase cargo capacity of the base vehicle.
Convert Air Conditioning Compressor to Air Compressor, to fill suspension air bags, etc.
Smaller Wheels, decrease the wheel size to increase low end torque and slightly lower the vehicle.
Electric Radiator Fan, as the vehicle will be used almost always at lower speeds.
High Output Alternator, for 12v audio system and other 12v DC powered items..