Project Hellraiser 2

Costing

   
 
 

This page will be used to track projects costs and should serve as a good reference for people wondering how much it costs to build a rock crawler from scratch.  Obviously prices change, good deals come along and sales occur so I have linked the original excel sheet for you to download so you can plug in your own prices as you plan/build.  For this build I highlighted the stuff I am re-using from my last buggy and tried to include the prices I paid (2005-2009 timeframe) and where I was in doubt I looked up today's 2010 price.   I tried to group the parts logically.  After seeing this I can see why turn-key rigs start around 40k!

 For reference the prices shown are for the full quantity shown (i.e. $600 for qty. 2 means each item cost $300).  Shipping, taxes and consumables are not included.  Obviously I am doing the labor myself.  If I had to pay someone I could easily see adding 3-400 hours billed at $75hr to the cost.

 One last thing, don't let your wife see the spreadsheet.  If she does walk in on you just hit the "Wife" tab at the bottom ;)

Make vs. buy is another debate.  I am to the point where I don't care to spend a weekend day fabricating a link mount bracket from scratch so I will be buying every bracket and tab I can get my hands on to save time.  When I originally built my buggy there wasn't very many places making tabs.  Fast forward 6 years and it seems like everyone and their mother has a CNC plasma cutter in their garage.  Pre-fab tabs are cheap and you can get all sorts of cool assemblies like the battery box pictured above for a hair over $30.

Category QTY Description  Cost  Vendor
         
Materials        
         
  10 22ft sticks of 1.50 x .120 wall DOM Tubing  $          85.00 Scrap from Work
  3 22ft sticks of 1.00 x .095 wall ERW tubing  $          15.00 Scrap from Work
  1 6 x 6 x .25 Steel Plate  $            2.50 Capitol Metals
  1 Honda Odyssey Rear Control Arm  $                 -   Scrap from Work
  2 4 ft stick of 1.25 x .125 wall sq. steel tubing  $            5.00 Scrap from Work
  2 BRK-1026 Two wrap around link brackets   $            9.00 Ballistic Fabrication
  4 Tube Couplers, 1.5" Tube  $          95.20 Ruff Stuff Specialties
         
Electrical        
  1 MISC-699-1 Ballistic 34/78 Optima Battery Box  $          39.99 Ballistic Fabrication
  1 Optima red top battery  $        129.00 Autozone
  1 Warn Ti9500 Winch  $    1,100.00  
  1 Aluminum Fairlead  $          50.00 A-Z Fabrication
  1 3/8"  x 100' Synthetic winch rope  $        250.00  
  4 100w headlamps  $          45.00 Ebay
  6 LED rock lights  $        150.00 Superbright LED.Com
         
Suspension        
         
  10 Weld Washers, 5/8"  $          20.00 Ruff Stuff Specialties
  10 Weld Washers, 1/2"  $          20.00 Ruff Stuff Specialties
  12 7/8" Chromoly Rod End, RH Thread  $        142.80 Ruff Stuff Specialties
  4 Link Tab, 3.0" Axle, Medium  $          15.64 Ruff Stuff Specialties
  4 Link Tab, Flat Bottom, Medium  $          15.64 Ruff Stuff Specialties
  8 Flat Bottom Shock Tabs  $          30.64 Ruff Stuff Specialties
  1 BRK-1013 Dana 60 kingpin Coil over / Shock mounts/gussets  $          11.00 Ballistic Fabrication
  1 BRK-1031 4-link adjustable Ballistic joint mounting system   $          34.99 Ballistic Fabrication
  2 MISC-690 Shock bungs (one pair)  $          26.00 Ballistic Fabrication
         
         
Front Axle        
         
  1 Rebuilt, full width Chevy Kingpin D60  $    1,500.00  
  2 Solid Axle D60 knuckles  $        400.00 Letz Roll Offroad
  1 Solid Axle keyed steering arms w/ Studs  $        190.00 Letz Roll Offroad
  1 Right and left D60 alloy inner axle shafts  $        410.00 Letz Roll Offroad
  1 D60 HD Diff Cover  $          90.00 Ruff Stuff Specialties
  1 D60 ARB  $        750.00 4 Wheeler Supply
  1 Air compressor  $          49.99 Costco
  2 Superior Stub Shafts  $        300.00 Letz Roll Offroad
  2 300m U-joints  $        300.00 Longfield
  1 5.13 gear set  $        250.00 4 Wheeler Supply
  1 Polyperformance 35 spline drive slugs  $        225.00 Polyperformance
  1 1410 driveshaft yoke  $          95.00 High Angle Driveline
  1 Double ended steering ram  $        500.00 Performance Offroad
  2 Ram clevis ends  $          95.00 Performance Offroad
  2 Ram Mounting Clamps  $          50.00 Performance Offroad
  2 Ram Hydraulic Lines w/fittings  $          30.00 Hose Express
  4 3/4 x 3/4" Rod ends for tie rods  $        104.00 Rodend Supply
  2 Tie rod for cylinder  $          50.00  
  4 3/4-16 weld in inserts  $          25.00 AA mfg
  2 3/4 ton disc brake brackets  $        180.00  
  2 3/4 ton brake discs, calipers, hardware  $        200.00 Checker Autoparts
  2 Racerunner 14" trvl, 2" emulsion coilovers   $        550.00  
  4 Coilover springs  $        156.00 Summit Racing
  2 Fox 4" air bumps  $        400.00 Polyperformance
  2 1.75" OD x 36" 7075 suspension link  $        300.00 Summit Machine
  2 1.50" OD x 36" 7075 suspension link  $        200.00  
  8 High misalignment spacers, 7/8 to 5/8"  $          64.00 Ballistic Fabrication
  4 7/8" rod ends  $          47.60 Ruff Stuff Specialties
         
Rear Axle        
         
  1 Rebuilt 14 bolt w/ dually outer hubs  $        350.00 Classifieds
  1 HD Diff Cover  $                 -    
  1 Overson mini-spool  $                 -    
  2 14 bolt disc brake brackets  $                 -    
  1 14 bolt axle truss  $        125.00 Ballistic Fabrication
  1 14 Bolt pinion guard  $          49.00 Forgot!?
  1 1410 yoke  $          95.00 High Angle Driveline
  1 5.13 gear set  $        250.00 4 Wheeler Supply
  2 Racerunner 14" trvl, 2" emulsion coilovers with res  $        620.00  
  4 Coilover springs  $        156.00 Summit Racing
  2 Fox 4" air bumps  $        400.00 Polyperformance
  1 27" Sway bar w/ arms  $        299.00  
  2 2" OD x 36" 7075 suspension link  $        320.00 Summit Machine
  2 1.75" OD x 36" 7075 suspension link  $        300.00 Summit Machine
  16 High misalignment spacers, 7/8 to 5/8"  $        128.00 Ballistic Fabrication
  8 7/8" rod ends  $          95.20 Ruff Stuff Specialties
         
Drive Train        
         
  1 99 Pontiac Grand Prix L67, 3.8l w/ Supercharger, PCM & Wire Harness  $    1,200.00 Classifieds
  1 Wire Harness Re-configured  $        300.00 Jim's Performance
  1 PCM programming  $        150.00 Jim's Performance
  1 Electric Water Pump (Meziere)  $        350.00 ZZP Performance
  1 3.4" Blower Pulley  $          99.00 ZZP Performance
  1 Blower serpentine belt (smaller than stock)  $          45.00 ZZP Performance
  1 Set colder spark plugs (2 heat ranges)  $          40.00 ZZP Performance
  1 Bored throttle boy  $        199.00 ZZP Performance
  1 Cobra head air intake, elbows and k&n filter  $        150.00 Ebay/Summit Racing
  1 Ported pass side exhaust manifold  $        119.99 ZZP Performance
  1 Power log (drv side exhaust manifold)  $        149.99 ZZP Performance
  1 Ceramic coated crossover pipe  $          59.99 ZZP Performance
  1 Muffler  $          89.00 Summit Racing
  3 2.5" OD header bends  $          36.00 Local
  1 2.5" OD exhaust tubing (6ft stick)  $          20.00 Local
  1 Flex coupler  $          30.00 Summit Racing
  1 V-clamp for exhaust hookup  $          25.00 Summit Racing
  1 Dual Pass, 26 x 19 Al. Radiator w shroud and dual 16" fans  $        650.00 Ron Davis
  1 Radiator Cap  $          10.00 Ron Davis
  1 SS Radiator hose kit  $          40.00 Ebay
  1 Electronic fan controller  $        140.00 Spal
  1 Modified CB steering pump  $        200.00 PSC
  1 High output alternator, 160 amp  $        200.00 Ebay
         
  1 10 Gallon Fuel Cell  $        110.00 Summit Racing
  3 Walboro Fuel Pickups  $          75.00 Summit Racing
  3 Submersible fuel lines  $          48.00 Napa
  1 20 ft EFI Fuel Line/Clamps  $          60.00  
  1 255 lph Electric fuel pump #VOR-8F002-265   $        216.00 Summit Racing
  1 40 micron fuel filter #SUM-230105   $          30.00 Summit Racing
  1 5 micron fuel filter #MAA-3160  $          85.95 Summit Racing
  1 Misc fittings/clamps  $          25.00  
         
  1 TF904 Transmission w/ Manual valve body and 2 rebuilds  $    1,200.00  
  1 Art Carr rockcrawler torque converter, 2500 stall  $        600.00 Art Carr
  1 Gated shifter  $                 -   Art Carr
  1 Trans Cooler w/fan  $        220.00 Summit Racing
  1 External transmission filter w/ temp sender  $          80.00 Summit Racing
  1 Passive transmission cooler  $          60.00 Ebay
  1 Misc cooler lines  $          25.00  
         
  1 Stake D300 Replace -a-case  $        699.00 Stak
  1 4:1 Gear set  $        600.00 LoMax 
  1 Twinstick  $        200.00 Stak
  1 32 spline rear output  $        350.00 LoMax 
  1 32 spline front output  $        175.00 LoMax 
  1 1350 CV flange  $        100.00 High Angle Driveline
  1 1410 32 spline flange  $          95.00 High Angle Driveline
  1 1350 CV rear drive shaft, 1410 joint on axle end  $        550.00 High Angle Driveline
  1 2 piece front drive shaft with 1410 joints, carrier bearing  $        700.00 High Angle Driveline
         
Interior        
         
  2 Beard Ultra Seats  $        740.58 ???
  1 PRP Preemi Seat  $        200.00  
  1 Steering wheel, shaft, oversized rod end, bracket  $        125.00 Summit Racing
  1 Steering column bracket  $          24.00 AA Mfg.
  3 5 point seat belt  $        300.00  
  1 shift light  $          50.00 Summit Racing
  1 Gauge set - Boost/Volt/Oil Pressure/Water Temp  $        400.00 Summit Racing
  1 Programmable Scan Gauge - OBD II code reader/reset  $        239.00 Aeroforce
  1 Switch panel  $          39.99 Cabela's 
  1 Dual master cylinder brake pedal assembly  $        239.00 Summit Racing
  1 Misc SS brake lines/fittings  $        225.00 Speedway Motors
  1 Gas pedal, linkage, high flex cable  $        150.00 Summit/Local
  1 Cutting brake lever  $        149.99 Polyperformance
         
         
Misc        
         
  4 Trailready Beadlocks, 17 x 9, 8 on 6.5 patter. 2.75" BS  $    1,600.00  
  4 BFG 39 x 17 Tires, Red Label  $    1,650.00  
         
         
         
         
         
    Grand Total  $  29,730.67  

 

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