Dodge Ram 3500 Overland Build

Driven To Wander

Adventurer
As a long time Expedition Portal follower, I am excited to contribute to the forum for the first time. This site has been a great inspiration to me.

After years of dreaming and researching and making some mistakes along the way, our plans to go around the world with a vehicle are finally getting some traction. The idea of an extended overlanding trip has been brewing in my head for a long time. In 1978, my parents packed our family car, a 1300 cc - 68 hp Fiat 124 and put my brother and me in the back seat and drove around Europe for 3 months. I was 9. That magical road trip sowed the seeds of the overlanding journey we are planning.

About 3 years ago, after a very long and frustrating day at work, I pitched the plan to my wife. She said “Sure, let’s figure it out” and it was on. We were living in Singapore at that time where even a Honda Civic comes with a $100.000 price tag. So all I could do was keep dreaming. When we moved to Canada we were (ok, I was) anxious to get going. So we purchased 2006 Toyota Tacoma 4x4 Dbl Cab TRD. It had less than 60K miles on it and was in great condition. It was fun to drive, nimble and getting great mileage. But it's gross combination weight rating (GVWR) was too much of an uphill battle. We would have needed so many modifications to carry a camper that could accommodate our family, that it became unrealistic for us. If it were like its cousin, the Aussie Hilux which has a 1 ton payload capacity and a diesel engine, it would have been perfect. After lots of upgrades and with a broken heart we sold the beloved Tacoma. Before we choose our next vehicle, we decided to first pick the camper.

We will be traveling with our 3-year-old toddler in tow so we want to have good protection against elements, enough space in our living quarters and we don’t want to pull a trailer. These three requirements quickly eliminated roof top tents and some of the best overlanding platforms like Toyota Land Cruiser and 4Runner. We are left with pickup trucks with campers or vans. Sportsmobiles were too expensive and we saw to many Vanagons in the back of the tow trucks. Finally, we want to be able to ship our vehicle in a shipping container rather than using Roll-on-roll-off (Ro-Ro) vessels. We decided on a Hallmark Everest as our camper of choice. We are picking up our camper in 2 weeks. I will report about the Hallmark under "Expedition Campers/Pop-up Truck Campers" forum.


The Rig

After yet another weeks of research, we decided on 5.9 Cummins powered Dodge Ram should be our truck. Finally we found one in great shape last April.


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  • 2007 Dodge Ram 3500 4x4 HD
  • 5.9 Cummins Turbo Diesel
  • 325 HP - 610 lb-ft torque
  • GVWR :10100 lbs
  • 103K miles
  • Rebuilt Transmission @ 81K miles
  • Fass Titanium Fuel Pump
  • Michelin LTX A/T Tires


Why did we choose Dodge Ram for a trip around the world where parts would be very difficult if not impossible to find outside North America? Well, it is a risk, but a calculated one we are willing to take. Here is a quick table of our decision making process and other used vehicles we have considered. I have put two of my favorite vehicles, Defender 130 and Hilux there also. Since they are not available to us in Canada they get 0 points for cost and they are there purely for comparison reasons.


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On a scale from 0 to 10, where 0 is no-way and 10 is awesome.​


A couple of other factors that swayed our decision were, Ram 3500’s big brakes and 5.9 Cummins engine’s ability to run with ultra low sulfur diesel (ULSD), low sulfur diesel (LSD) or high sulfur diesel which is still the norm in some countries we want to visit.


The Build

This build is going to be about preparing the truck for a long overlanding journey with limited funds. Truck is in great shape overall as a base rig. One can easily blow the budget on the truck upgrades and be left with nothing for the trip. I have to admit I have a soft spot and must be careful about it.

There will be a bit more detail in the build section of our travel blog here http://driventowander.com/category/build/, along with links to where we got all the parts, equipment, and services we use to complete the build.
 
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Driven To Wander

Adventurer
ARB On-board Air Compressor Install

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Finally, I had some time to finish this project. I have chosen ARB CKMA12 High-Output model for my on-board air compressor. Unit comes with full wiring harness, mounting hardware, pressure limit switch and detailed instructions.

Although this model is compact and highly configurable, it was still a challenge to find a spot to mount it under the hood of the Ram 3500. I found just big enough space behind the driver side headlight. Here is step by step instructions;

1. To remove the headlight, remove these two bolts first.

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2. Pull the plastic cap in the wheel house to reach and remove the 3rd bolt.

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3. With a flat tool wrapped in soft tissue give a little nudge to pop the headlight out.

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4. Remove the harnesses going into the headlight.

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This is the part of the frame where I am going to mount the compressor. To give myself more room to work, especially for drilling, I decided to remove the windshield washer fluid reservoir and the air circulation hose.

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5. This is first of 2 bolts that hold the reservoir.

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6. This is the second bolt. After detaching the sensor cables, just lift the reservoir and lay it down to the left.

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7. Loosen the clamps on both end of the hose and move it out of the way.

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8. Use the metal base plate that comes with ARB Compressor as a guide to drill the holes.

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Driven To Wander

Adventurer
ARB On-board Air Compressor Install part II

9. Prep the compressor. I am using ⅛ male to ¼ compression adaptor, orange teflon tape and 150 psi rated air tubing. Rotate the manifold to create best angle so the hose is not bent.

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10. Attach the air filter and the pressure sensor. Use generous amount of orange teflon tape.

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The bar I am going to mount the compressor is 2” thick. I am using 2.5” bolts, self locking nuts, locking washers and plastic washers. I have primed and painted the base plate black to prevent corrosion.

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11. After removing the 4 bolts that holds the compressor (yellow arrows), I mounted the base plate and mounting bracket to the bar. I used plastic washers to dampen the vibration and the noise.

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12. Attach the compressor body to the mounting bracket.

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13. Attach the ARB cable harness to the compressor. I used 1/2 inch split loom to protect the cables.

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D45

Explorer
Ditch the front unit bearings on that AAM 9.25

Its a ticking time bomb that will fail with NO WARNING......leaving you stranded or causing the wheel/tire to rip off the knuckle

Free spin kit is $1500, but needed.
 

Driven To Wander

Adventurer
Hi D45, thanks for the tip about the bearings, I will definitely look into it. Compressor is being used for Firestone Air Bags and OBA at the moment. I have not put the lockers yet. Hopefully coming soon.
 
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Driven To Wander

Adventurer
Rocker Switch Panel Install

After installing ARB On-board Air Compressor last week, I needed to put its switch somewhere on the dashboard. ARB uses V-Series : Contura rocker switches made by Carling Technologies. They are plenty different colors, legends and mounting panels for them available on the market. I decided to use Daystar KU80011 20 Amp Blue Light Rocker Switch Kit and modular Rugged Ridge 17235.20 Black Rocker Switch Housing Kit possible future expansion.

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I have decided to install the switches on the under dash knee kick panel. Here is step by step instructions;

1. After removing the knee kick panel and measuring twice, I drilled the corners of the area where the housing will be placed.

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2. Using Dremel Tool I cut the opening. Note to self, never use 0.5 mm pencil to mark. It scratches the surface.

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3. I am tapping into headlight/dimmer switch output (orange with brown stripe) to get positive current.

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4. It is the second wire between the black with orange stripe and the white with yellow stripe wires.

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5. When dimmer is turned down all the way, Multimeter reads 2.4 V.

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6. When dimmer is turned up all the way, Multimeter reads 11.4 V.

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7. Install the Rugged Ridge 17235.20 Black Rocker Switch Housing Kit.

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8. Install the Daystar KU80011 20 Amp Blue Light Rocker Switches.

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jerstw

Adventurer
Great intro to the project and the journey. I have never owned a 5.9 Cummins so take this with a grain of salt but I have had two acquaintances both with 5.9 24 valves same as your generation Ram both convert to the DynaTrac Free-Spin hub kit. Sounds like the OE bearing assembly, as D45 stated, can be an issue if / when it fails in the field. While the investment is significant I have yet to hear anyone regret doing the freespin kit. I know there is at least one other company that offers such a kit but the name escapes me at the moment.

Best of luck with the adventure and look forward to reading more.
 
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Driven To Wander

Adventurer
Rocker Switch Panel Install Part II

9. Prepare the area behind the kick panel. Here is the opening before I used Dremel Tool to enlarge it.

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10. Here is the area after the cut.

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11. Project is complete.

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Regcabguy

Oil eater.
Great base vehicle.
When you get your camper or final weight figured out seriously consider a suspension system from Carli or Don Thuren. Either company will supply the necessary coils,springs and specially valved shocks to enable the truck to last.
The Dynatrac American-made freespin kit with Warns was an all time low of $1599 on Black Friday. I would imagine they will repeat the sale Christmas.
Spyntec,another good kit is $1500 everyday.
 

Driven To Wander

Adventurer
On-board Air Tank Install

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I started this project thinking that I would either weld the air tank to the truck or drill some holes into the frame to install it. But, as I was researching camper tie-downs, I realized Torklift simply clamps their front tie-downs to the frame. I like that idea better so I designed a bracket for the 2.5 Gallon Viair Air Tank that is rated for 200 PSI. This tank has 6 1/4" NPT ports and 15.3 pounds. Here are step by step instructions:


1. Get three zinc plated 10" L-brackets and two 4" L-brackets. 10" L-brackets are symmetrical on both end. Cut the third 10" L-bracket in half so you end up with 2 bars.

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2. The frame on the Dodge Ram 3500 is 3" thick. I clamp the frame with 10" L-bracket, the half bar and 4" L-bracket using 3.5" bolts. I am using 4" L-bracket as a support to reduce to stress on the 10" L-bracket. Holes with yellow arrows line up and need to be enlarged to allow 3.5" bolts. Holes with red arrows are used to mount the air tank. I primed and painted everything to prevent corrosion.

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3. Here I am testing the location and making final adjustments. I am using a Viair Tank Port Fittings Kit and a generous amount of Orange Teflon Tape.

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4. Mount the brackets with 3.5″ bolts, washers and self locking nuts.

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5. Everything is now mounted. Connected the tank to the ARB Air Compressor and filled it up to 100 PSI and tested the fittings with soapy water to make sure nothing leaks. Whole setup sits about 1.5 inches lower then the frame, but it is not the lowest part of the truck.

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