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Full Race's "Gen 2.5" Raptor build
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<blockquote data-quote="full-race geoff" data-source="post: 2056805" data-attributes="member: 6864"><p><strong>Chassis</strong></p><p>At this point - the turbos were installed, the engine sounded awesome and I couldn't wait to take the truck out to play for its maiden voyage. This was the part where things got real. My truck had obviously seen some off road use, and it felt OK in a straight line but wonky on turn-in. I brought it back to the shop and put it on the lift then removed the skid plates to visually inspect every component in detail</p><p></p><p>Immediately my eyes were drawn to a small area of discoloration at the Strut tower / UCA mounts... then I had one of those "Oh s#!t how did i miss that?" moments and discovered it has the typical hairline crack at the coil bucket and the accompanying warp in the frame rail behind the bucket / RH UCA mount area.</p><p></p><p>Anyone considering to buy a used raptor - This is where the Gen2 frame will fail as our friends at RPG have seen many times. This was an unwelcome surprise, but like I said by purchasing a truck based on roof type and paint color - I was prepared for the worst... and here we are.</p><p></p><p>[ATTACH=full]465863[/ATTACH]</p><p></p><p>I tend to bite off more than I should chew for my personal projects so this type of headache is right up my alley. the options for repairing something like this:</p><p></p><p>1. pay a body shop to pull the frame and weld the buckets (nope)</p><p></p><p>2. cut/weld a chunk of new gen 3 frame rail Ford part # ml3z-5019a-b - but then I'd spend a ton of time and be stuck with leaf springs (I hate leaf springs)</p><p></p><p>-or-</p><p></p><p>3. use this as an opportunity to continue my theme of Gen 3 upgrades by completely swapping an entire 2021+ raptor frame Ford part # pl3z-5005a-d under my Gen 2 truck. This results with the highly refined Gen3 front strut tower/UCA buckets, 5 linked coil sprung rear end, lower front diff for better CV angles, plus a bit more shown below. all in the simple gen2 form factor</p><p>[ATTACH=full]465825[/ATTACH] <a href="https://parts.lakelandford.com/a/Ford_2023_F-150/132424955__7326298/FRAME--COMPONENTS/MA12120.html" target="_blank">https://parts.lakelandford.com/a/Ford_2023_F-150/132424955__7326298/FRAME--COMPONENTS/MA12120.html</a></p><p></p><p>If you read my previous posts, and assumed that fully committing to an entire frame and 5 linked axle swap would be the only way to go - trust your instincts. I started researching everything I could find to cross reference things like the gen 2 vs gen 3 gas tank mounts, abs mounts, fuel line/brake line routings, cab mounts etc.</p><p></p><p>Now a gen 3 frame + rear 5 links + rear axle is shipping out this week (missing the front end components). Plus now I'll get to see what will fit and what will not and share that info with the community.</p><p><img src="/styles/default/xenforo/smilies/signs1.gif" class="smilie" loading="lazy" alt=":signs1:" title="Signs1 :signs1:" data-shortname=":signs1:" /></p><p></p><p></p><p>Gen 3 frame differences shown in Red then Blue</p><p>Gen 3 suspension differences shown in yellow:</p><p></p><p>[ATTACH=full]465847[/ATTACH]</p><p></p><p></p><p></p><p>next I talked to our friends at RPG about my plan. and apparently they are a bit ahead of me because they already did this exact frame swap on their gen2 truck and offer frame gusseting plates that I plan to weld on before the frame goes under.</p><p></p><p>[ATTACH=full]465860[/ATTACH]</p><p></p><p>And without further ado - here's the latest purchase:</p><p></p><p>[ATTACH=full]465859[/ATTACH]</p><p></p><p>there are some big questions I have and will address in the coming weeks:</p><p></p><p>gen 3 spindles are taller. can i machine a taller misalignment spacer for the arms I already have? i dont think that will work 100% but it may be 99%. do i swap to a gen3 spindle and if yes, what do I do for a wheel bearing and IWE? (gen3 is different). would like to go +2" wider in the front, tempted by the BOLT kit - however im not sure I want fabricated steel arms/spindles</p><p></p><p>gen 3 front diff mounts lower in the chassis. is there any difference beyond that? i dont yet know.</p><p></p><p>gen 3 steering rack is different. unclear to me how</p><p></p><p>gen 2 airbumps will not fit the gen 3 frame (rear coil spring upper seat is in the way) I have the icon gen2 bump stop kit on there currently, was thinking I'd try and re-use that. I expect it won't bolt up and would need to weld it to the gen3 frame instead of bolting up.</p></blockquote><p></p>
[QUOTE="full-race geoff, post: 2056805, member: 6864"] [B]Chassis[/B] At this point - the turbos were installed, the engine sounded awesome and I couldn't wait to take the truck out to play for its maiden voyage. This was the part where things got real. My truck had obviously seen some off road use, and it felt OK in a straight line but wonky on turn-in. I brought it back to the shop and put it on the lift then removed the skid plates to visually inspect every component in detail Immediately my eyes were drawn to a small area of discoloration at the Strut tower / UCA mounts... then I had one of those "Oh s#!t how did i miss that?" moments and discovered it has the typical hairline crack at the coil bucket and the accompanying warp in the frame rail behind the bucket / RH UCA mount area. Anyone considering to buy a used raptor - This is where the Gen2 frame will fail as our friends at RPG have seen many times. This was an unwelcome surprise, but like I said by purchasing a truck based on roof type and paint color - I was prepared for the worst... and here we are. [ATTACH type="full" alt="1725549720355.png"]465863[/ATTACH] I tend to bite off more than I should chew for my personal projects so this type of headache is right up my alley. the options for repairing something like this: 1. pay a body shop to pull the frame and weld the buckets (nope) 2. cut/weld a chunk of new gen 3 frame rail Ford part # ml3z-5019a-b - but then I'd spend a ton of time and be stuck with leaf springs (I hate leaf springs) -or- 3. use this as an opportunity to continue my theme of Gen 3 upgrades by completely swapping an entire 2021+ raptor frame Ford part # pl3z-5005a-d under my Gen 2 truck. This results with the highly refined Gen3 front strut tower/UCA buckets, 5 linked coil sprung rear end, lower front diff for better CV angles, plus a bit more shown below. all in the simple gen2 form factor [ATTACH type="full" width="810px" alt="1725506866352.png"]465825[/ATTACH] [URL]https://parts.lakelandford.com/a/Ford_2023_F-150/132424955__7326298/FRAME--COMPONENTS/MA12120.html[/URL] If you read my previous posts, and assumed that fully committing to an entire frame and 5 linked axle swap would be the only way to go - trust your instincts. I started researching everything I could find to cross reference things like the gen 2 vs gen 3 gas tank mounts, abs mounts, fuel line/brake line routings, cab mounts etc. Now a gen 3 frame + rear 5 links + rear axle is shipping out this week (missing the front end components). Plus now I'll get to see what will fit and what will not and share that info with the community. :signs1: Gen 3 frame differences shown in Red then Blue Gen 3 suspension differences shown in yellow: [ATTACH type="full" width="450px" alt="1725545485177.png"]465847[/ATTACH] next I talked to our friends at RPG about my plan. and apparently they are a bit ahead of me because they already did this exact frame swap on their gen2 truck and offer frame gusseting plates that I plan to weld on before the frame goes under. [ATTACH type="full" alt="1725548166454.png"]465860[/ATTACH] And without further ado - here's the latest purchase: [ATTACH type="full" alt="1725548064174.png"]465859[/ATTACH] there are some big questions I have and will address in the coming weeks: gen 3 spindles are taller. can i machine a taller misalignment spacer for the arms I already have? i dont think that will work 100% but it may be 99%. do i swap to a gen3 spindle and if yes, what do I do for a wheel bearing and IWE? (gen3 is different). would like to go +2" wider in the front, tempted by the BOLT kit - however im not sure I want fabricated steel arms/spindles gen 3 front diff mounts lower in the chassis. is there any difference beyond that? i dont yet know. gen 3 steering rack is different. unclear to me how gen 2 airbumps will not fit the gen 3 frame (rear coil spring upper seat is in the way) I have the icon gen2 bump stop kit on there currently, was thinking I'd try and re-use that. I expect it won't bolt up and would need to weld it to the gen3 frame instead of bolting up. [/QUOTE]
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Full Race's "Gen 2.5" Raptor build
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