Project Hellraiser 3

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 (yellow) 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 included if known.  Obviously I am doing the labor myself.  If I had to pay someone I could easily see adding 1000 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/shop.  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 Notes
           
Materials          
  10 22ft sticks of 1.50 x .120 Wall DOM Tubing  $             85.00 Scrap from Work For chassis
  2 23ft sticks of 1.50 x .120 Wall DOM Tubing  $           171.62 Advanced Metal Sales For chassis/Links
  5 20 Ft Sticks of 1.50 x .120 ERW Tubing  $           143.09 Advanced Metal Sales For chassis
  3 22ft sticks of 1.00 x .095 wall ERW tubing  $             15.00 Scrap from Work For chassis
  1 6 x 6 x .25 Steel Plate  $                2.50 Capitol Metals Motor Mounts
  1 22ft sticks of 1.00 x .095 wall ERW tubing  $             23.31 Advanced Metal Sales  
  1 20 Gauge Mild Steel Sheet  $             59.06 Advanced Metal Sales  
  1 86 LBS of Steel, 11lbs Al Sheet for Skid Plates  $             72.40 Industrial Metal Supply  
  2 4 ft stick of 1.25 x .125 wall sq. steel tubing  $                5.00 Scrap from Work Seat Mounts/Motor Mounts
  2 BRK-1026 Two wrap around link brackets   $                9.00 Ballistic Fabrication Hinge for Engine Cage
  4 Tube Couplers, 1.5" Tube  $             95.20 Ruff Stuff Specialties Engine Cage
  80 Small Trick Tab w/ 1/4" Hole  $           110.00 Ruff Stuff Specialties Panel Mounting
  22 Link Tab, Flat Bottom, Medium  $             47.14 Ruff Stuff Specialties Shock, Crossmember, Skid Mounts
  25 Small Trick Tabs  $             36.08 DT Products Inc.  
  6 RH & LH 7/8 Tube adapters for 1.50 x .120 wall tubing  $           108.00 Ruff Stuff Specialties  
  1 Misc Brackets, tube End Caps, Steering Bracket  $             99.02 A&A Mfg  
  2 Tube Couplers, 1.5" Tube  $             64.00 Advanced Metal Sales  
  1 10 YJ Spring Bushings, 1.5" Tube Flanges, 7/8-14 Jam Nuts  $             70.06 WFO Concepts Crossmembers & Skid Plate Materials
  1 Welding Wire, New Switch for Miller 175   $             41.00    
  3 11lbs Spool Wlding Wire, .030  $             72.65 Advanced Metal Sales  
  1 Tig Welder Gas Lense & Tungsten  $             60.00 US Air Weld  
  6 Bottle CO2 for MIG  $           137.24 Advanced Metal Sales  
  1 Bottle Argon for TIG  $           105.00 Advanced Metal Sales  
  3 14" cutoff Wheels  $             15.00 Harbor Freight  
  1 Misc Steel  $             18.05 Capitol Metals  
  1 5/8 Drill Bit  $             16.95 Lowes  
  1 Notchmaster tube Notcher & 2 Hole Saws  $           283.59 Medford Tools  
  1 Misc Nuts, Bolts, Flap Discs, Step Drill, Digital Angle Finders  $             91.66 Harbor Freight  
  1 2.5" & .50 Dimple Die  $             66.00    
  1 Misc Grade 8 Harware, Lock Nuts, Washer, Lock Washer, 5/8 Link Bolts  $           154.13 Mcmaster Carr  
  1 #10 weld nuts, pan head screws, weld on tie down  $             41.35 Mcmaster Carr  
  1 Waterjet 1/8" Tabs, Basket, Rad Hold Down  $           215.00 Marzee  
  1 Waterjet 3/16" Shock Tabs, Front Susp Tabs, Seat Mounts, Misc Brkts  $           325.25 Marzee  
  1 Taps, Hole Saws, Misc Harware  $             88.50 Mcmaster Carr  
  1 Waterjet parts for front axle & hood  $           226.80 Marzee  
  1 Misc Interior Hardware, Radiator Padding, Weld Nuts  $             98.00 Mcmaster Carr  
  2 6 x 6 x .25 Gusset  $                4.26 Advanced Metal Sales Lower Link Mount Braces
  2 2 x 2 Steel Hinge  $                2.00 Advanced Metal Sales Rear Storage under Kids Seat
  1 Misc Steel and Hardware  $             18.62 Home Depot  
  3 .75 x .125 x 36" HRS  $                7.85    
  1 55lbs of 5052 Aluminum sheeting and 86lbs of CRS Sheet  $           201.79 Industrial Metal Supply Hood, roof and boatside panels
  1 Cold Roll Bar Stock, Misc steel tabs  $                5.74 Industrial Metal Supply  
  1 Misc Flap discs, Cut off wheels and Chop Saw Wheel  $             57.69 Leigh Valley Abrasives 15 Flap, 15 cutoff, 1 Chop Saw
  1 Misc Flap discs and Cut off wheels  $             30.66 Leigh Valley Abrasives 9 Flap Discs, 3 Cutoff
  1 Hardware for grab Handles, washers for body panels  $             46.83 Mcmaster Carr Bushings, Shaft Collars, Sealing washers
  3 Walter 4.5 x 3/64 Cutoff wheels  $             11.23 Advanced Metal Sales  
           
Electrical          
  1 MISC-699-1 Ballistic 34/78 Optima Battery Box  $             39.99 Ballistic Fabrication  
  1 Sears Diehard Platinum PM-2  $           204.87 Sears  
  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    
  1 LED Rocklight Kit  $             99.00 Vision X  
  2 Solstice Prime 10 Watt LED Light Pods w/ Y cable  $           280.00 Vision X  
  1 22" Light Bar   $           600.00 Used  
  1 Wiring Connectors, Wire Loom  $           102.87 Performance Connection Systems  
  1 Wire Crimper, Circuit Breakers  $             48.00 Waytek Wire  
  1 Misc Weatherpak Conenctors  $             88.59 Performance connection Systems  
  1 Viair 350C Air Compressor, .5 Gallon tank, filler hose  $           246.02 Polyperformance  
           
           
           
Suspension          
  14 Weld Washers, 5/8"  $             28.00 Ruff Stuff Specialties Link tab reinforcements
  10 Weld Washers, 1/2"  $             20.00 Ruff Stuff Specialties Shock tab reinforcement
           
  4 Link Tab, 3.0" Axle, Medium  $             15.64 Ruff Stuff Specialties Front axle lower link mounts
  4 Link Tab, Flat Bottom, Medium  $             15.64 Ruff Stuff Specialties Front axle, upper link mounts
           
  1 BRK-1013 Dana 60 kingpin Coil over / Shock mounts/gussets  $             11.00 Ballistic Fabrication Front axle shock mounts
  2 BRK-1031 4-link adjustable Ballistic joint mounting system   $             69.98 Ballistic Fabrication Lower link mounts
  2 MISC-690 Shock bungs (one pair)  $             26.00 Ballistic Fabrication Shock mounts
Front Axle          
           
  1 Rebuilt, full width Chevy Kingpin D60  $       1,500.00    
  2 Solid Axle D60 knuckles  $           400.00 Letz Roll Offroad  
  1 Arctec Steering Arms  $           300.00 Artec  
  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  $           370.00 Longfield  
  2 Longfield Spindle Bushings  $             45.00 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  
  1 High Pressure Hose Assy & Fittings  $             58.65 Parker Store  
  4 7/8 x 3/4 Rod Ends For Tie Rods  $             95.00 Ruff Stuff Specialties  
  2 Tie Rod Material for cylinder     1.50 x .120 Wall DOM
  1 Steering Valve  $           356.00 Performance Offroad  
  1 Steering wheel  $             55.00 Summit Racing  
  1  .750-20 Weld-in stubs   Performance Offroad Systems ST201A 
  1 .750-20/.750-20 U-JOINT   Performance Offroad Systems UA20201 
  1 .750-20/.735-36 U-JOINT    Performance Offroad Systems UA-20102
  1 Steering Column for Orbital, Short w/ .750-36 Spline  $           259.00 Performance Off-road  
  1 Steering Wheel Disconnect  $             24.00    
  1 Steering column bracket  $             24.00 AA Mfg.  
  2 3/4 ton disc brake brackets  $           180.00    
  2 3/4 ton brake discs, calipers, hardware  $           200.00 Checker Autoparts  
           
           
           
  2 1.75" OD x 36" 7075 suspension link  $           300.00 Summit Machine  
  2 1.50" x .120 Wall DOM x 36" Long Suspension link  $             32.00    
  8 High misalignment spacers, 7/8 to 5/8"  $             39.20 Ruff Stuff Specialties  
  8 7/8" rod ends  $             95.20 Ruff Stuff Specialties Link ends lower F&R, upper rear
  2 ORI 16" Travel Struts  $       1,260.00    
  2 20" Limit Straps  $             35.00    
           
Rear Axle          
  1 Rebuilt 14 bolt w/ dually outer hubs  $           350.00 Classifieds  
  1 HD Diff Cover  $                    -     Included with axle
  1 Overson mini-spool  $                    -     Included with axle
  2 14 bolt disc brake brackets  $                    -     Included with axle
  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  
  1 Tormax Double Splined Axles, 35 Spline Drive Flanges  $           900.00 Letzroll Offroad  
           
  2 2" OD x 36" 7075 suspension link  $           320.00 Summit Machine  
  2 1.50" x .120 Wall DOM x 36" Long Suspension link  $             32.00    
  16 High misalignment spacers, 7/8 to 5/8"  $             39.20 Ruff Stuff Specialties  
  8 7/8" rod ends  $             95.20 Ruff Stuff Specialties Link ends lower F&R, upper rear
  2 ORI 16" Travel Struts  $       1,260.00    
  1 18" Limit Strap  $             17.50    
           
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  
           
Motor 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 Taylor Plug Wires  $             26.95 Summit Racing TAY-53010
  1 Plug Boot Protectors  $             51.95 Summit Racing SUM-350119
  1 Bored throttle boy  $           199.00 ZZP Performance  
  1 Cobra head air intake, elbows and k&n filter  $           150.00 Ebay/Summit Racing Intakehoses.com
  1 Camaro Headers for 3.8L  $           434.00 Ebay  
  1 Electric Water Pump (Meziere)  $           350.00 ZZP Performance  
  1 VS Cam, Install Kit, Valve Springs, Pushrods, Etc  $       1,345.22 ZZP Performance  
  1 Head Gaskets  $             69.57 Checker  
  1 Modular Pulley System w/ 3.3" pulley  $             99.00 ZZP Performance  
  1 2.5 Quart Oil Accumulator  $             99.00 FOA  
  1 Oil Filter Relocation Kit  $             51.95 Summit Racing TRD-1150
  1 K&N Oil Filter  $             10.85 Summit Racing KNN-HP-3001
           
  2 Magnaflow Mufflers  $           141.58 Summit Racing MPE-14416
  3 2.5" OD header bends  $             36.00 Summit Racing  
  1 2.5" OD exhaust tubing (6ft stick)  $             40.00 Summit Racing  
  2 Flex coupler  $             76.00 Summit Racing SUM-642510
  2 V-clampS for exhaust hookup  $             88.00 Summit Racing DTC-60-912250S
  1 2.5" Balance Tube Kit  $             35.00 Summit Racing SUM-642025
  2 45 Degree Elbow  $             43.90 Summit Racing WLK-41437
  1 50 Ft Header Wrap  $             37.88 Summit Racing THE-11002
  6 Collector Gasket, 2.5" ID  $                5.94 Speedway 91013702
  8 Collector Ring, 2.5" ID  $             23.92 Speedway 91013369
           
  1 Ron Davis Dual Pass, 26 x 19 Al Radiator w shroud and dual 16" Spal fans  $           650.00 Ron Davis  
  1 Radiator Cap  $             10.00 Ron Davis Not included with the radiator!
  1 Aluminum Overflow Tank  $             59.95 Summit Racing SUM-300101-W
  1 Gates Flexible Radiator Hose, 1.50 x 25"  $             28.70 Summit Racing GTR-52425
  2 Gate Flexible Radiator Hose, 1.50 x 20"  $             27.98 Speedway 39525480
  1 Silicon Radiator Hose, Straigh, 6" x 1.5" ID  $                9.99 Speedway 9171006-1.50
  1 20ft 1.50 x .049 Wall stl tubing  $             14.00 Advanced Metal Sales For coolant lines
  1 Gates Flexible Radiator Hose, 1.50 x 17"  $             13.99 Speedway 395-25478
  1 90Deg Steel Rad Tube, 1.50 OD  $             15.99 Speedway 917-1000-1.50
  1 12" Long 90 Deg Silicone Rad Hose  $             19.99 Speedway 917-1010-1.75
  1 Boost Gauge Plumbing Kit  $             10.00    
  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  $           216.00 Summit Racing  VOR-8F002-265 Non S/C can use MSD-2225
  1 40 micron fuel filter  $             30.00 Summit Racing  SUM-230105 Before fuel pump
  1 5 micron fuel filter   $             85.95 Summit Racing MAA-3160 After fuel pump
  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 Included with trans
  1 B&M Trans Cooler w/fan  $           203.75 Summit Racing BMM-70297
  1 External transmission filter w/ temp sender  $             80.00 Summit Racing  
  1 Passive transmission cooler  $             60.00 Ebay  
           
  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 Repair 1350 CV, lengthen shaft by 3", New U-joints  $           156.00 TAD Driveshafts  
  1 Front Driveshaft - 1410 Joints, 6" travel  $           450.00 High Angle Driveline  
           
  1 Shift Boot, Twinstick  $             29.99 4WS.Com 18606.06
           
Plumbing          
  1 Misc AN Fittings/Adpaters/Reducers/Unions  $           575.46 Summit Racing  
  1 20 Feet -6 Socketless Hose  $             69.95 Summit Racing AER-FCN0620
  1 20 Feet -8 Socketless Hose  $             69.95 Summit Racing AER-FCN0820
  1  -6 Flare W/ 1/8 NPT, 2 -8 Pushlock 90's  $             29.31 Parker Store  
           
Interior          
  2 Beard Ultra Seats  $           740.58 Polyperformance  
  1 PRP Preemi Seat  $           200.00 PRP  
  2 5 Point Harness  $           168.00 4WS.Com Crow
  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 Monitors L67 Vitals (knock sensors)
  5 Rocker Switches w/Covers  $             54.40 12Volt Guy  
  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  
  1 Front Seat Heaters  $             89.00 Jegs Made by Warmseats, used 1 pad per seat
  1 ATV Seat Heater  $             54.99 Jegs For Preemie seat
           
Misc          
  6 KMC Beadlocks, 17 x 9, 8 on 6.5, 4.25 Offset  $       1,620.00 A to Z Fabrication  
  1 32 Piece splined lug nut set w/ sockets  $             35.69 Desert Rat  
  5 42 x 15 x 17 Pitbull Rockers  $       2,000.00 Let'z Roll  
           
  1 5" Mirrors with brackets  $           114.57 Liquid Iron Industries  
  1 Billet Foot Pegs  $             35.85 Dan's Performance Foot rests and rear grab handle
           
  1 Paint and Supplies, Misc Hardware  $             27.66 Ace Hardware  
  1 4 Quarts Rustoleum gloss black paint, misc supplies  $             85.00 Home depot Paint for body panels and chassis
  1 2 cans hi-temp exhaust paint  $             19.00 Checker Paint for exhaust parts
  1 1 Gallon Gloss Black, Acetone & Painting Supplies  $             56.00 Home depot  
           
  1 Fire Extinguisher Mount  $             49.00 Vison X  
  6 Billet Breather Assy  $             90.90 North East Xtreme Tech Dif, Trans, T-case, Radiator,  Fuel Cell Breathers
           
Fluids 4 Gallons Distilled Water  $                4.00    
  1 Gallon Napa Universal Tractor Fluid  $             15.29 Napa  
  4 Quarts Redline Shockproof Gear Oil  $             53.80 Summit Racing  
  2 Gallons Gear Oil  $             22.00 Walmart  
  1 Gallon ATF  $             12.00 Walmart  
           
           
    Grand Total  $     39,455.24   Sure does add up!

 

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