Ford Ranger Raptor transformed into a lightweight super-tourer

Building a tourer today usually takes a well trodden path, ultimately ending with an absolute rig holding everything you’d ever want while you’re away from the place you actually have everything you’d ever need.

Before the 4×4 industry’s big bang that exploded thousands of products onto the market to satisfy the consumer-tourer, 4×4 owners did things much simpler, and for good reason. Weight. In simple terms, more of it meant it was harder on the rig, and took much more fuel to move it all, limiting range. Engines were upgraded with more power, with chassis becoming heavier still for higher GVMs, and the gear list longer still. And the cycle continues.

1

While it seems the favoured choice is to go heavy and hedonistic, there’s still those who pack light and limited, but Mandurah local Bo Clayton entered the chat with a third alternative: a super tourer that packs the most power in his chosen model range, along with the race-inspired Fox suspension, but with a fully spec’d lightweight canopy ready to lap the map. While this seems like mixing oil and water, Bo had a plan to pull it off. 

“I wanted a comfortable vehicle to travel Australia in and what I got for the price I thought was value for money,” Bo explains. “If you look at all the extras the Raptor has over the lower-spec vehicles, I believe it was a cost effective price.” 

Experienced 4×4 builder

Coming from a decent list of past 4x4s which included the previous 2022 Raptor, a 1982 Bronco, a 2004 Hummer H2, two Hiluxs, a Surf and a 2020 LC200 VX, Bo had a good idea what sort of a challenge he was in for. “The 200 Series turned out really well but she ended up being four tonnes, and I did not enjoy driving it that much,” he admits. 

1

Taking on the range-topping 2024 Ranger Raptor to build a tourer from was still a bold choice, bearing in mind it came with a reduced payload just above 700kg straight out of the factory. This represented a restriction of 200kg less than the marque’s leaf-sprung alternatives, mainly due to its race inspired all coil suspension. The Raptor is also the heaviest in the Ranger range, albeit with the most power, but with no adjustment from Ford to the final GVM allowance. 

“The biggest challenge was to keep the Raptor under the 750kg payload with the super lightweight canopy, but I managed to accomplish that task,” Bo says. “I have all the weighbridge receipts, so I know it’s correct.”

Lightweight canopy

To give his Raptor a decent chance to stay within its GVM, Bo decided on the Mode 4×4 canopy, which is a subdivision of parent company Zone RV caravans.

According to Mode 4×4’s website, these composite canopies come in at a svelte 220kg, and are a bolt-on service-body style, so there’s no additional weight from a tray or headboard, with the wheel arches and toolboxes bolting straight to the underside of the canopy.

Installing the canopy was taken care of by David and Jayden at Mac 4X4 in Cockburn, south of Perth. While they were at it the crew also installed an Offroad Animal bull bar, plus a complement of 13 Stedi spot, bar and work lights. The job of colour coding to the Raptor’s Code Red hue was handed to Nathan, Vaughan and team at Calmack Panel & Paint in Greenfields, who also turned their attention to detailing the bull bar and bash plates, and modifying the front mudflaps. 

1

While all this sounds like it was trucking along seamlessly, there were the usual supply delays and workshop availability issues. When asked what he’d do differently Bo said, “I’d compile most of the components and store them for about five months until I had enough to start and finish the build in a better time frame. This would save a bunch of money for a start, so you can imagine just how hard it is to complete a build when you have assorted components coming from all over Australia and overseas, all arriving at different times.”

Once the canopy was painted Bo engaged 4Signs in Mandurah to draw up his own design of custom graphics with inlaid skull detailing, plus a PPF wrap. “It was the first time they had done it,” says Bo. “The two brothers Tae and Yung pulled it off with all my requests. Good people and a great job.”

Diving into the fitout, Bo installed the shelves and electrical system himself, with help from Brad at Whitcroft IT who supplied knowledge along with the Victron components and 300Ah lithium battery. Three-colour dimmable lighting helps find things at night, while a Rockarmor 3000W inverter (with external display) helps power any high current devices. Bo has fitted an ice making dual-door 95L Gecko fridge (negating the need for the extra weight of a fridge slide), a full slide-out pantry, plus a slide-out prep table for the gas cooker.

Mode 4×4 canopy

Being of a composite design, the Mode 4×4 canopy is made up of an aluminium supporting structure to which lightweight composite panels are bonded, much like the construction of caravans from parent company Zone RV.

This means there are some limitations to where loads can be applied. The maximum internal load carrying is 350kg, with a dynamic weight of 150kg being allowed on the roof (350kg static). This drops to 110kg with one spare wheel bolted to the rear, and 75kg should you require two spares, or jerry cans etc. of a similar weight to a spare wheel. 

In Bo’s case, there’s minimal weight stored up top with his fishing gear, solar panel and awning currently installed. With the current 35-inch tyre and billet bead-lock spare wheel, jerry can and ladder mounted on the back wall, this would make any more roof-mounted accessories an exercise in weight management. 

1

Upgraded suspension

Suspension-wise, the Raptor comes standard with trick Fox Racing live valve shocks, and coil springs on all four corners.

These are electronically controlled 2.5-inch internal bypass shocks with in-cab mode selection. One very cool feature is the Ford software controls damping on the rear shocks to resist squatting on heavy acceleration. Having the GVM approaching redline was enough reason for Bo to add in the extra support of bellow-type airbags to assist with heavier canopy loads, or when towing, while also upgrading to G.O.A.T. Offroad front upper control arms and two-inch lifted front springs.

Kris, Cody and the team at Precision Offroad 4×4 in Wangara carried out the work including the wheel fitting. “They also re-programmed the suspension height in the computer so all the Ford sensors worked correctly with the upgrades, including the height of the front lights for oncoming drivers as well as the shocks sensing the correct ride height of the vehicle,” Bo says. 

1

Engine upgrades

To keep things moving at an acceptable pace, Ford’s petrol-fed EcoBoost V6 twin-turbo powerplant provides the mumbo up front, driving through a 10-speed auto ’box, however Bo found a few items in need of attention.

“I installed a set of Process West turbo induction and intercooler piping as I did not like the way the Ford rubber hoses flexed and distorted under load,” he says. These were joined by an aftermarket windscreen washer reservoir, and then further modified to allow the fitment of the hard pipes. 

Fresh air comes from a Safari Armax snorkel piped into the Fabulous Fabrications twin foam filter airbox. Out of the factory the Raptor can change its exhaust note at the touch of a button, so little was done to the exhaust other than a pair of bolt-on four-inch dual tailpipes. An initial tune yielded 480hp (397hp standard) and 725Nm (583Nm), however final fettling is due to be carried out after a longer run-in period. “I have heard of all sorts of things going wrong with the Raptors, but touch wood so far I have had no issues at all,” Bo says.

Rounding out the under-bonnet mods, Bo says, “I extended the breathers from the gearbox, front, centre, and rear diffs and the winch to just under the bonnet line. For the other small jobs I must thank a good friend Tim Gunn (Sik Em Wrex Racing). He’s my go to person for odd jobs as it’s done once and done correctly.”

1

Interior tech and comfort

Being the top-of-the-line offering from Ford, you’d expect the cabin to be a great place to be, and you’d be right, with lots of leather and race-style seats, plus more infotainment than most would need, it really does present as good-to-go. Bo set about further enhancing the interior and slotted in a Stedi light switch pod above the central screen, which also provides an access point for his GME 370C UHF radio. 

Replacing the now redundant rear-vision mirror is a triple camera system monitor. This reveals front, rear and in-cabin views, while recording and allowing playback all from the one unit. 

63

Verdict

After taking the path far less travelled and building such an outstanding level of tourer, Bo is in the final stages of his overall plan. “I’m building a small pop-top caravan of 1800kg that I am working on now. It’s an old 2004 Coromal SEKA 535 XC Pioneer built in Perth and is fully off-road capable.

The trip is to last for a number of years if possible, [so] I’m going to take my time and spend the majority of my retirement on the road seeing sights, travelling off-grid and meeting some awesome people.”

Keep an eye out for his rig as he makes his way around our map, and if you can catch him, say G’day.