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

Russel Battles Build

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

Eric's 3.4l Powered Buggy

 
 
 

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.

Looking for a shorter wheelbase? This chassis can go down to a 100" wheelbase without modifications to the sub frame.  Shorter wheelbases are possible but I would recommend shortening the belly tubing for anything under 100" wheelbase.  The above pictures in orange show a 100" wheelbase and 37" tires.

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 ran a dual triangulated 4 link front and rear utilizing 2.0" coilovers and provide the numbers to duplicate this link setup. 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 see the FAQ.  

The plans you will receive are laser printed on 11 x 17 sized sheets of paper.  I have broken down the entire chassis into stages and include a suggested order of assembly guide to help you build your chassis.  The guide lists how I would tackle the chassis build and notes when you should mock up major systems and suggests other systems that need to be considered at that stage.

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. See the FAQ here for information on compensating for different die sizes. It is actually a very quick and easy adjustment to accommodate larger bend radius dies.

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) 20ft sticks of 1.625 x .120 DOM, and (2) 20ft 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 $110 which includes all drawings on 11 x 17 paper; shipping is included in that price to any confirmed address in the Continental US. If you would like two different sets of plans you can select the pick 2 option; please specify the second set in the notes field. I do not offer electronic versions. See below for international purchasing instructions. As a bonus I also throw in 4 free DVD's: BTG Volume 1, 3, 3.5 & 4 so you can see what your new chassis can do. the bonus DVD offer is only available to buyers in the US.   

All packages ship USPS, please allow 1-2 weeks for domestic orders although actual ship times are usually much faster.

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

HR2 Pickup Chassis Plans Shipping Options

HR2 Buggy Chassis Plans Shipping Options

International customers please read -

If your mailing address is in Canada, Australia or New Zealand you can pick that option from the drop down box above. The customs form number you will receive will serve as a tracking number and as of July of 2015 I have had all packages sent to those countries track to their destination as shown in the screenshot below. 

All other orders going to any country not listed above will need to submit payment as noted below. The customs form number you will receive will show when the package is dropped off at the US postal office and when it leaves US customs but I cannot guarantee it will continue to update with your package status once it gets handed off to your local postal service.

That said, I have only had two packages go missing in the last fifteen years and a few that have required upwards of 8 weeks to reach their destination so my track record is really good. I can provide the customs form number which will show the date the package was submitted to the US postal service but once it leaves the US that number no longer gives any useful information.

 You can enter the customs form number into the tracking field on the USPS website or here.

Payment directions for orders going to any country not listed in the drop down box above:

 I require payment via PayPal using the "Send Money" or "Gift" option. Once you manually log into PayPal you can select send money, enter my PayPal address: chris@azrockcrawler.com. Next you should then see two options for what the money is for, select the "I'm sending money to family or friends." (see picture below). Some countries may show this as a "gift" or "personal payment" option either of which are also acceptable.  If you do not have this option I cannot ship to your country.

Chassis plans for international customers are $140 shipped anywhere in the world. Once you have made payment, please send me an e-mail to chris@azrockcrawler.com and list the items you want as well as your shipping address.

Please make sure to note the items you want and double check your shipping address. Shipping times vary so I always tell people to allow up to 8 weeks for delivery (40 working days). I have had packages reach Australia and Russia in as little as a week but there are always the occasional straggler.  If your order still hasn't arrived after 8 weeks I can give you a discount on another duplicate order.

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