The Lobster Wagon: 1st Gen Crew Cab

Chris Begley of Riverside, California, has been building custom off-road machines for more than two decades. A welder by trade, his fab shop Luxury Prerunners builds high-end offroad rigs that bring together form and function. From roll cages and suspensions to full vehicle overhauls, Begley and his team of fabricators build long travel race trucks, tube chassis buggies, and even the occasional VW Baja Bug.

THE LOBSTER WAGON

A few years back, Begley was in the market for a new daily commuter to go to and from the shop and haul his family around. While most would expect him to build a late-model prerunner stuffed full of modern creature comforts and the latest technology, Begley went retro, overhauling a 1990 Dodge Ram D250 Cummins 4×4 from the ground up. The truck had been passed down from his father and had nearly 350,000 miles on the motor. At that point in time it was collecting dust in his driveway, so Begley decided to breathe new life into this family heirloom.

First problem: The truck was a single cab, so hauling his family of five around would be a tight squeeze on the factory bench. Begley started out hunting the local online trading posts for a Ramcharger body in decent shape before coming across a crew cab ’84 Dodge Ram dually 2wd pickup that was being parted out. $500 later, he had the cab and chassis in tow back to his shop where they got to work turning it into a custom crew cab Cummins capable of all his day-to-day needs.

THE CONVERSION

Dodge never offered a 1st gen crew cab Cummins truck; the crew cabs were phased out in 1985 and the 5.9L Cummins wasn’t introduced until 1989. While there were a few ways to go about the conversion Being a fabricator, Begley wanted to use the best parts from both trucks. After stripping both down to rolling chassis, careful measurements were taken and the frames were cut. The front chassis belonged to his 1990 to utilize the 5.9L Cummins and 4wd. The rear came from the 1984, using the longer frame section to accommodate the crew cab and long bed. The two frames were overlapped and welded inside and out before being boxed in for extra rigidity. With the crew cab fi tted and the bed reinstalled, the next step was cleaning up the body panels that had been plagued with waves and ripples throughout the sheet metal. With the help of Shawn Hengstebeck, the body panels were straightened out and prepped for paint.

The front fenders were opened up for extra tire clearance. One and a half inches were sectioned out of the front and backside of the fenders and reattached to retain the factory fender contour. The extra 3 inches of clearance allows room for the 37- inch meats to be fi tted with the BDS lift kit. For primer and paint, Begley turned to Matt Hutcheson Design to lay down the Lobster Red color, a factory Mopar option on the late-model Jeeps. The chrome bumpers, grille, mirrors and trim were refi nished in gloss black. Inside, the interior was kept clean and simple. With roll-up windows and a manual transmission, this truck is full of old school cool factor without all the late-model fl uff. The front and rear benches were reupholstered in black to match the fresh black paint on the dash and door panels. A layer of Dynomat coats the fl oorboards underneath of the new black carpeting to fi nish off the interior for a factory showroom new look. In the bed, a DIY spray-on bed liner kit was laid down for extra scuff protection when he’s hauling parts and gear around.

RAISING THE BAR

The stock leaf springs served this truck well over the years, but with plans for 37s Begley needed extra altitude. Front and rear BDS 5-inch leaf springs were installed along with custom built shackles to net a total of 6 inches of lift. Up front, a pair of shock hoops were built from 4130 tubing to mount a set of FOX 2.5 triple bypass shocks. In the rear, a pair of FOX 2.0 IFP shocks were added to help control the rear suspension. For steering, Begley upgraded to Off Road Design’s crossover steering kit to improve steering angles and strength. With the suspension complete, a set of 37×12.50 Nitto Terra Grappler G2 tires were fitted, mounted up on 20×10 KMC XD Rockstar III wheels. The setup is comfortable for Begley to drive around town and reliable for any on or off-road trips he takes with the family.

FIRST GEN FIVE NINE

Under the classic sheet metal the original 5.9L Cummins diesel is alive and kicking. With roughly 350,000 miles on the odometer, this first gen 5.9L is just getting broken in. Most of the miles on this truck were logged by the Begley family so it has seen its fair share of family memories, back country adventures, and daily commutes. Begley kept the Cummins relatively stock. The 6BT has the stock Bosch VE44 rotary injection pump and Holset turbo. Begley built his own killer dowel pin (KDP) kit to help keep from having any issues down the road with the 12V Cummins. Exhaust comes from RBP with a modified 4-inch side exiting system that dumps just in front of the passenger rear tire. Power is sent back through the Getrag 5-speed manual transmission to the NP205 transfer case. JE Reel driveshafts transfer power to the front kingpin Dana 60 and rear Dana 70. Both axles were fitted with 4.11 gears and Nitro X-treme diff covers. Chris Begley has outdone himself with this build. This super clean crew cab Cummins has tons of cool factor and room for the whole family. We dig the Lobster Wagon. DW

FREQUENTLY ASKED QUESTIONS

What were some of the unexpected issues the author encountered during the truck restoration project?

During the truck restoration project, the author uncovered several unforeseen complications. Initially, they opted to remove the cab and box to simplify driveline removal by mimicking the assembly line approach of dropping components from above. However, upon further inspection, they discovered that the truck’s chassis wasn’t as sturdy as anticipated, a sign of the vehicle’s high mileage.

While the main frame was in satisfactory condition, numerous other issues emerged. These included deteriorated cab mounts, visible remnants of previous repairs, and non-functional shocks. Additionally, the springs appeared worn out, the bushings were excessively worn, and there were numerous leaks throughout the vehicle. This array of unexpected problems prompted the author to question the truck’s overall condition and the wisdom of the purchase.

How did the author balance the costs and emotional investment involved in the truck restoration?

Balancing the costs and emotional investment in a truck restoration requires a deep passion and an understanding that it’s driven more by love than logic. The author approached this balance by focusing on the rewarding aspects of the project rather than getting bogged down in financial calculations.

By intentionally choosing not to add up expenses until the project is complete, the author avoids the potential stress or discouragement that might come from knowing the total investment upfront. This strategy allows them to continue investing both emotionally and financially without the fear of making spur-of-the-moment decisions to halt the project.

In essence, it’s about prioritizing the joy and satisfaction of seeing the truck come to life over the possibly daunting financial implications. The thrill and fulfillment of the restoration journey outweigh the numbers on a spreadsheet—making it a true labor of love.

What challenges did the author face with their initial truck purchase and how did these influence future restoration plans?

When the author acquired their initial truck, they faced several challenges that eventually shaped their future restoration plans. At first glance, the truck seemed lackluster. Its power output was surprisingly low, especially considering its substantial weight of 6,000 pounds. The absence of easily identifiable components under the hood, like spark plugs, added to the confusion and dissatisfaction.

Despite these initial setbacks, the author began to appreciate the truck over time, particularly enjoying the robust sound of the aftermarket stacks. However, three primary issues persisted: the truck lacked a manual transmission, it wasn’t equipped with dual rear wheels (dually), and the regular cab was too cramped for comfort. These factors made the driving experience less than ideal, albeit the vehicle was affordable and functional.

Throughout that year, the author delved into research, discovering that the model was available with more desirable configurations in the past, such as full four-door crew cabs, dual rear wheels, and manual five-speed transmissions. This newfound knowledge sparked the idea of sourcing a donor cab that could be modified and installed onto the existing truck frame. Thus, these initial grievances not only motivated future upgrades but also laid the foundation for a comprehensive restoration project to transform the truck into a more versatile and satisfying vehicle.

What was the author’s strategy for enhancing the truck’s power and performance capabilities?

Up front, a pair of shock hoops were built from 4130 tubing to mount a set of FOX 2.5 triple bypass shocks. In the rear, a pair of FOX 2.0 IFP shocks were added to help control the rear suspension. For steering, Begley upgraded to Off Road Design’s crossover steering kit to improve steering angles and strength.

To boost the truck’s power, a strategic selection of enhancements was undertaken. The engine was equipped with a stock turbo, complemented by a twin ram intake, ensuring optimal air flow. Stage 2 injectors were installed to increase fuel delivery, paired with 60 PSI valve springs and an advanced timing setup to optimize combustion efficiency. To maintain engine health, an oil filter relocation kit was added for improved accessibility and performance.

Additionally, the modifications included a 3000 RPM governor spring kit and taper cut delivery valves, which provided a balanced fuel delivery for increased horsepower. A custom fuel plate was also integrated, offering precise control over fuel flow and power output.

This combination of suspension and engine upgrades resulted in a well-rounded enhancement, improving both the truck’s handling and performance capabilities. The changes not only bolstered power but also ensured reliability and control, aligning with the goals for versatile and robust truck performance.

What modifications and upgrades did the author make to the truck’s driveline and engine?

Under the classic sheet metal, the original 5.9L Cummins diesel is alive and kicking. With roughly 350,000 miles on the odometer, this first-gen 5.9L is just getting broken in. Most of the miles on this truck were logged by the Begleyfamily, so it has seen its fair share of family memories, backcountry adventures, and daily commutes. Begley kept the Cummins relatively stock. The 6BT has the stock Bosch VE44 rotary injection pump and Holset turbo.

However, to enhance reliability and performance, several upgrades were made. Begley built his own killer dowel pin (KDP) kit to help prevent future issues with the 12V Cummins. For improved exhaust flow, a modified 4-inch side-exiting system from RBP was installed, which dumps just in front of the passenger rear tire.

Power is sent back through the Getrag 5-speed manual transmission to the NP205 transfer case. But the quest for better towing capacity and reliability led to considering a transmission swap. After extensive research, a NV5600 6-speed transmission from a newer model was identified as a more robust option, though Begley ultimately maintained the original setup.

JE Reel driveshafts transfer power to the front kingpin Dana 60 and rear Dana 70 axles. Both axles were fitted with 4.11 gears and Nitro X-treme diff covers. Recognizing the Dana 70’s limitations under increased torque, Begleycontemplated upgrading to a Dana 80 from a newer Ram model for enhanced durability, especially for heavy hauling.

Additionally, the consistency in wheel setup was addressed. To match the dual rear wheels (DRW) configuration, Begley considered a DRW hubbed Dana 60 front axle to achieve uniformity and ease in carrying spares, ensuring the truck’s front end matched the robust aesthetic of the rear.

These thoughtful modifications and the balance between maintaining original elements and modern upgrades reflect Begley’s dedication to both preserving family history and enhancing performance.

What was the overall strategy for achieving the desired power and reliability?**

The strategy involved systematically replacing and upgrading key components to reach a target of 200 HP while ensuring long-term reliability. This included a transmission swap, engine upgrade, and axle enhancements, all tailored to meet specific performance goals.

How was the front axle addressed in relation to the dual rear wheels?**

To maintain consistency with the dual rear wheels and avoid the inconvenience of carrying multiple spares, a DRW hubbed Dana 60 front axle was sourced. This approach simplified the setup and ensured a uniform appearance.

What changes were made to the rear axle?**

The rear axle was upgraded from a Dana 70 to a Dana 80. This change was necessary to handle higher torque outputs and enhance the truck’s durability, especially given the non-dually nature of the original axle.

What engine modifications were made?**

The existing engine was swapped out due to its limitations and wear. Instead of just upgrading the injection pump, a complete engine swap was performed. A low-mileage 1997 12V Cummins engine was selected, offering a cohesive system and better performance for the intended use.

Why was the transmission replaced?**

The original G360 transmission was deemed insufficient for long-distance towing needs. After consulting with a knowledgeable family member and conducting extensive research, it became clear that a more robust solution was necessary. Thus, an NV5600 6-speed transmission was chosen for its improved towing capacity and reliability.

How did the author ensure compatibility and functionality of new parts with the existing truck structure?

After stripping both down to rolling chassis, careful measurements were taken and the frames were cut. The front chassis belonged to his 1990 to utilize the 5.9L Cummins and 4WD. The rear came from the 1984, using the longer frame section to accommodate the crew cab and long bed. The two frames were overlapped and welded inside and out before being boxed in for extra rigidity.

To ensure compatibility and functionality, a meticulous selection of parts was crucial. The journey started with identifying the need for more reliable towing power and long-distance hauling capabilities. Extensive research led to the decision to replace the existing transmission with a 6-speed unit known for its durability and performance.

Engine and Powertrain Considerations

The engine was another focal point. The existing motor showed signs of fatigue, especially with its limited top-end power. A deep dive into potential upgrades revealed that a motor swap would be more cost-effective than merely replacing the injection pump. Thus, a late-model mechanical engine with low mileage was sourced, ensuring a harmonious fit with the new transmission.

Addressing Axle and Wheel Concerns

Attention then turned to the truck’s axles. The rear axle, previously identified as a weak link, was replaced with a more robust unit designed to handle increased torque. Similarly, the front axle was swapped to accommodate dual rear wheels, ensuring uniformity and reducing the need for multiple spare tires.

Each component was carefully selected and integrated to create a cohesive and reliable system, ready to meet the demands of enhanced performance and structural integrity.

What considerations were made for performance and reliability?

The focus was on achieving a performance target of 200 HP for the truck’s specific hauling needs. This involved selecting components like a Cummins engine and robust axles that collectively enhanced both performance and reliability for long-distance travel.

How was compatibility ensured?

Compatibility was ensured by sourcing parts that matched the truck’s requirements, such as a DRW hubbed Dana 60 front axle to align with the upgraded rear axle, thereby maintaining a uniform and functional setup.

What issues were identified and how were they resolved?

Limitations of the Bosch VE injection pump and the weaknesses of the Dana 70 rear axle were identified. These were resolved by opting for a motor swap to a Cummins engine with a more powerful injection pump and upgrading to a Dana 80 rear axle for better torque handling.

Why were specific parts chosen?

The NV5600 transmission was selected for its superior performance and compatibility with the intended use. A Cummins motor with low mileage was chosen for its potential to deliver the desired power and reliability, despite having a less preferred injection pump model.

What research was conducted?

Extensive research was undertaken to evaluate various options for towing power and reliability. This led to the conclusion that the NV5600 6-speed transmission from a 1999-2005 truck was the optimal choice over the Getrag for long-distance hauling.

What components and systems did the author focus on when preparing the truck for reassembly?

With the crew cab fitted and the bed reinstalled, the next step was cleaning up the body panels that had been plagued with waves and ripples throughout the sheet metal. With the help of Shawn Hengstebeck, the body panels were straightened out and prepped for paint.

The engine and transmission received their share of attention as well. For ease of installation, the engine and transmission were bolted together before being carefully lowered into the frame. This heavy-duty operation required a tractor, two engine cranes, and a handful of guiding hands to maneuver the 1700-pound duo into place. While the engine stayed mostly stock at 180 HP, subtle enhancements like a twin ram intake and a new exhaust manifold began to sneak in.

The front fenders were opened up for extra tire clearance. One and a half inches were sectioned out of the front and backside of the fenders and reattached to retain the factory fender contour. The extra 3 inches of clearance allows room for the 37-inch meats to be fitted with the BDS lift kit. For primer and paint, Begley turned to Matt Hutcheson Design to lay down the Lobster Red color, a factory Mopar option on the late-model Jeeps.

Attention then turned to the fuel system. The original tanks were cleaned and painted, with a secondary tank added to support long trips without frequent stops. A clever adaptation involved sourcing a Ramcharger SUV fuel tank, chosen for its compatibility with the existing frame structure. This required custom fabrication of cross members and straps, alongside a new pump activated by a cab switch, allowing seamless transfer between tanks.

The chrome bumpers, grille, mirrors, and trim were refinished in gloss black. Inside, the interior was kept clean and simple. With roll-up windows and a manual transmission, this truck is full of old-school cool factor without all the late-model fluff. The front and rear benches were reupholstered in black to match the fresh black paint on the dash and door panels.

Electrical and monitoring systems were upgraded to accommodate the dual-tank setup, utilizing live gauges to ensure precise fuel management. Meanwhile, the truck’s paint job, after a prolonged wait, was finally completed, allowing the frame and components to be reassembled.

A layer of Dynomat coats the floorboards underneath the new black carpeting to finish off the interior for a factory showroom new look. In the bed, a DIY spray-on bed liner kit was laid down for extra scuff protection when he’s hauling parts and gear around. The exhaust system was meticulously measured and inspected to ensure optimal fit and performance, rounding off this comprehensive rebuild.

How did the author decide on and implement a new paint job and bodywork for the truck?

With the help of Shawn Hengstebeck, the body panels were straightened out and prepped for paint. The front fenders were opened up for extra tire clearance. One and a half inches were sectioned out of the front and backside of the fenders and reattached to retain the factory fender contour. The extra 3 inches of clearance allows room for the 37-inch meats to be fitted with the BDS lift kit.

Realizing that after the driveline and chassis work, a fresh paint job was essential, a media blaster using baking soda was employed to strip the body panels clean. This preparation was crucial for achieving a flawless finish and ensuring that the paint would adhere properly.

For primer and paint, Begley turned to Matt Hutcheson Design to lay down the Lobster Red color, a factory Mopar option on the late-model Jeeps. The chrome bumpers, grille, mirrors, and trim were refinished in gloss black.

The process was meticulous. After blasting, the parts were sent to a reputable painter known for his work on high-profile cars, ensuring the quality and precision required for such a project. During the assembly, a minor setback occurred when the doors and fenders did not match perfectly color-wise. This was promptly addressed with a repaint, ensuring a seamless appearance.

Inside, the interior was kept clean and simple. With roll-up windows and a manual transmission, this truck is full of old school cool factor without all the late-model fluff. The front and rear benches were reupholstered in black to match the fresh black paint on the dash and door panels. A layer of Dynomat coats the floorboards underneath the new black carpeting to finish off the interior for a factory showroom new look.

With the exterior and interior perfectly coordinated, the truck exudes a blend of classic style and modern functionality, showcasing the thoughtful decisions made at every step of the restoration process.

What adjustments were made in response to these challenges?

To rectify the color mismatch, the parts were repainted before being installed, ensuring a consistent and visually appealing finish.

What challenges or issues were encountered during the process?

During the installation of the doors and fenders, a color mismatch was discovered, indicating an issue that needed to be addressed before final assembly.

Who was chosen to perform the painting, and why?

A painter in Bracebridge, Ontario, was selected due to his expertise with SEMA cars, ensuring the truck would receive a professional and high-quality paint job.

How was the decision made to repaint the truck?

The decision to repaint arose logically after completing the driveline and chassis work, as it became apparent that a fresh coat of paint was necessary to complement the newly refurbished components.

What preparatory steps were taken before painting?

The truck’s frame was thoroughly stripped and sandblasted to remove old paint and rust. Following this, a media blaster using baking soda was employed to ensure the body panels were clean and ready for painting.

What motivated the author to begin restoring a first generation Dodge Cummins Ram truck?

A few years back, Begley was in the market for a new daily commuter to go to and from the shop and haul his family around. While most would expect him to build a late-model prerunner stuffed full of modern creature comforts and the latest technology, Begley went retro, overhauling a 1990 Dodge Ram D250 Cummins 4×4 from the ground up. The truck had been passed down from his father and had nearly 350,000 miles on the motor. At that point in time, it was collecting dust in his driveway, so Begley decided to breathe new life into this family heirloom.

His journey into the world of Cummins wasn’t just about practicality; it was a passion that took root in 2003. Back then, his father had suggested—more like insisted—that his first vehicle be a robust pickup, perfect for a farm kid. The 1990 model, equipped with a Cummins engine and initially acquired for its snow plow capabilities, became Begley’s canvas for exploration and learning.

As he delved deeper into the mechanics and history of his vehicle, Begley discovered that this wasn’t just any truck. It was a piece of automotive history. Intrigued by the rare full four-door crew cabs available in the old Ram body style, he embarked on a quest to find a donor cab to enhance his project. This search was more than just a hunt for parts; it was a journey into the past, uncovering stories of conversions done in northern Alberta, where only a handful of these trucks were ever crafted.

Through research and dedication, Begley transformed what was once a dusty relic into a living tribute to both family legacy and automotive ingenuity. His project was not merely about restoration but about creating something unique—a testament to his enduring fascination and the rich history behind these iconic machines.