Hellraiser 2

Chassis Plans

 

 

 
 
 

 

Check out Project Hellraiser 2

which will cover the build up of one of these chassis.

Estimated Chassis weight - 325 lbs

Ed's Buggy Build

LS2 & Atlas

Specs

2,983lbs without driver
105” wheelbase
20.5” belly clearance
78.5” to top of cab
55” o.d. wide chassis
17x9” Trailready Beadlocks
39.5” BFG Krawlers
PCS Steering and hydro-boost brakes
14” Coilovers
4 link front and rear
35 spline 9” axles,Detroits, 5.86 gears
GM 6.0l, 4L60e 4.3 Atlas
Warn M6000 winch

 
 
 

Most of us get into four wheeling using a pickup truck yet despite that there are very few chassis out there that maintain a pickup truck look.  So I set out to design a chassis that had a functional bed to use for storage or mounting components.  I plan on building up one of these chassis this summer so this page will grow as I start into the project.  For reference the pictures above show a 110" wheelbase.

 

This chassis is also available "buggy" style with tapered rear down tubes. Both the pickup and buggy 2 seaters utilize a sub frame that is based off of my original 3 seater design but it is wide open to allow for all sorts of interiors.

Customizing the chassis is very straightforward, so for example the bed can be wider, longer, or shorter, etc.  The chassis I am building from these plans is even deviating further with the addition of a 3rd seat. The blueprints of the pickup will detail two front end options, one low and one higher.  Either would be good candidates for a cut down OEM grill if you wanted to follow thru with the truck theme.

Specs:  Outside of rocker to outside of rocker is 55.62", outside of door bar to outside of door bar is also 55.62".  Belly to highest point on the roof is 53.62" and length from front bumper to rear most tube is 139". Estimated chassis weight is 300-350lbs depending on bracing.

As always some of the advantages of my designs include:

The ability to pull the transmission and transfer case without pulling the motor (via the lower skid plate).

No bars near your head (unlike many homebuilt chassis designs).

A cockpit that is big enough to keep you from hanging outside of the chassis when seated.

A suspension that works excellent for both crawling and climbing.

Motors - As per the FAQ:

Short block Chevy V8 w/ TH350 Shown

Pretty much anything can be made to fit.  4 cylinders are no problem and most 60 degree V6's are actually more compact than a lot of the inline 4's currently out there (Suzuki 1.3/1.6, Toyota 2.4/2.7l, etc).  About the only engines that would give me pause are 90 degree V8's like a Ford 5.4L or 4.6L since they are so darn wide. That said It is easy to make adjustments to the chassis so if you did have a blown 5.4L and wanted it in the chassis you could as long as you were willing to put up with a wider front end.  Inline 6's present another problem - length.  You'd have to stretch the nose of each chassis a few inches (assuming a front mounted radiator) except for the BMP 2 seater which was designed with a Jeep 4.0l drive train in mind.

If you go with a rear mounted radiator you should be able to fit just about anything.

For reference my 3.8L/904/D300 is roughly 54" long (pulleys to rear output), 28" Tall (oil pan to top of motor) and 22" wide at the valve covers.

Axles: Whatever you desire.

Suspension: The skies the limit. I run a dual triangulated 4 link front and rear utilizing 2.0" coilovers. Wheelbase in the plans is approximately 110" and with 40" tires the belly is approximately 21" above the ground. The wheelbase and belly clearance can be changed to suit your needs. For further suspension information please read thru all of my project buildups starting with Project BMP up thru Hellraiser 4 as well as my 4 link write ups in the tech section.

Things to keep in mind:

1. I make no warranties of any kind for the performance or durability of this chassis.  You are buying plans only. If you chose to fabricate something using these plans you assume all risk in the fabrication and operation of the project.

2.  You will need a basic knowledge of tube bending and access to a tube bender, welder, chop saw, etc. Access to a plasma cutter or cutting torch would be very helpful but is not required.  The chassis is designed around 1 5/8 tubing with a bend radius of 4.5"***.  Larger tubing  or bend radii could be used with some adjustments to the initial tube lengths.  there are no bends over 90 degrees,

*** It has been brought to my attention that the 4.5" radius die is no longer available from JD2. If using a 5.5" radius die you need to start all 90 degree bends an inch sooner (you can scale bends smaller than 90 degree's back from there) and the cut lengths can be approx .40" less than what is shown on the drawing.   

3.  The plans are meant to be a guide.  Since there is no way to get the bends to match the plans %100 expect to have to make small adjustments.  The plans do have suggested cut lengths and start points for the bends.  It will be your responsibility to cope the tube ends.  In spots where there are straight braces I usually provide a recommended tube size and length, however in most cases your best bet is to measure the distance between the nodes to determine the actual cut length.

4.  The plans only cover the dimensions of the basic chassis.  This means gussets, mounting tabs, suspension related mounts on the axles, body panels, component mounts, and all interior mounting tubing, etc are your responsibility. 

5.  I will include a recommended list of material for the basic chassis.  You may want to purchase additional material if you would like to leave extra material on the cuts or if you feel you may have to re-do a section of tubing.

For costing purposes I used approximately 8 sticks of 1.625 x .120 DOM, and 2 sticks of the following: 1.50 x .095 and 1.50 x .120 for the main chassis bracing. To save money you can get away with using HREW for any piece of tubing that does not contact rocks.

The plans cost $85 which includes shipping to anywhere in the Continental US and Canada.  For payment via credit card, debit card or PayPal click on the "Buy Now" button below.   As a bonus I also throw in 2 free DVD's (currently BTG Volume 3 & 3.5) so you can see what your new chassis can do. the bonus DVD offer is only available to buyers in the US. International orders are $98.

Note- you do not need a PayPal account to use your debit or credit card.

HR2 Pickup Options

HR2 Buggy Shipping Options

I also offer a discount for chassis plans buyers on the other DVD's I sell.  This offer is only valid if you purchase the DVD's at the same time as the plans. Buying all 3 remaining DVD's saves you $20 over the single price. Shipping is free.

Additional DVD Options

If you have any questions feel free to send an e-mail to sales@azrockcrawler.com,