Project Lead Sled - Part 1 - 2009 Dodge Ram - Ektensive Metalworks

1. After assessing what was hanging below the frame, the cutting of steel commenced. Up front, the removable control arm support was unbolted and the attending ears were cut flat to the pivot. Two small caps were made from plate steel and welded in place for strength.

1. After assessing what was hanging below the frame, the cutting of steel commenced. Up fr

One of the things we love to see is a custom truck completely flat on the ground with a killer set of wheels that look literally sucked up into the fenders. The stance can be hard to achieve, with some trucks being more difficult to work on than others. The main issue in achieving that in-the-weeds look is the diameter of the wheels and tires chosen. Fitting fairly diminutive 20-inch or 22-inch wheels under a fullsize truck does not require anywhere near the amount of modifications that a 24-, 26- or even 28-inch wheel and tire combination would need to clear.

With that in mind, we present you with Lead Sled, our '09 Ram in reborn form. Over the last four years, the truck has seen three sets of wheels and tires, plus two different suspension systems. Add to that, two custom paintjobs, plus a fender bender or two, and our poor Ram was in need of a serious makeover to feel like the tough truck it once was. For our first installment, we traveled to Houston, Texas, to see Bill Carlton and the crew at Ekstensive Metalworks. Ekstensive has been getting big trucks to lay low for years and we were certain that if there was a crew that could help us, it was the boys in Texas. A short 24-hour road trip later and we were standing with Mr. Carlton in one of the service bays at Ekstensive running down what we wanted to achieve with the truck while he just kept nodding his head and saying, "I got it man, quit worrying about it." He was right, and now our truck is one of the lowest and sickest-looking late-model Rams in the country. This is how they did it.

2. A tubular support was bent to go around the oil pan and welded between the control arm mounts, effectively allowing the same support as factory designed but much higher above the ground.
2. A tubular support was bent to go around the oil pan and welded between the control arm
3. Pulling a straight line across the front crossmember marked it for cutting. It was cut just to the bottom of the control arm pivots to maximize ground clearance.
3. Pulling a straight line across the front crossmember marked it for cutting. It was cut
4. Plating the crossmember gave it all its strength back.

5. Dodge trucks are notorious for extreme amounts of negative camber when laid out. To combat that issue, the upper control arm mounts were raised considerably, putting the front alignment into proper position for extremely lowered driving. You can also see the upper airbag mount welded in place.
5. Dodge trucks are notorious for extreme amounts of negative camber when laid out. To com
6. To measure for the shock mount, a steel spacer was used to simulate a collapsed airbag between the lower control arm and 'bag mount.
6. To measure for the shock mount, a steel spacer was used to simulate a collapsed airbag
7. Ekstensive makes its own lower control arms for air suspension, but leaves the mounting area blank to be drilled as necessary depending on the ’bag placement. Here, the measurements were being taken to correspond with the airbag’s mounting.
7. Ekstensive makes its own lower control arms for air suspension, but leaves the mounting

8. Completely collapsed, the Firestone 'bag was straight and true.
9. Both tie-rod ends were converted to Heim joints and bolted to the steering knuckle with 1/2-inch Grade 8 bolts after drilling out the stock taper. The spacers were machined to length to place the tie rods parallel with the control arms at ride height, minimizing bumpsteer.
9. Both tie-rod ends were converted to Heim joints and bolted to the steering knuckle with
10. The same measurement above and below were then cut. Bolting the 26-inch wheels on and raising the wheel up, allowed measurements to be taken on what the tire would hit at full drop. Everything from the front supports to the firewall had to be cut in a circumference greater than the tire to ensure adequate space.
10. The same measurement above and below were then cut. Bolting the 26-inch wheels on and

11. Sheetmetal was cut to fit the now huge holes in the firewall. Seam sealer coated anywhere two points were welded together and everything was sprayed with black enamel to hide it from view.
11. Sheetmetal was cut to fit the now huge holes in the firewall. Seam sealer coated anywh
12. Ever-popular trailer fenders were welded into place to add structural strength back in the front of the truck.
12. Ever-popular trailer fenders were welded into place to add structural strength back in
13. Many of the underhood accessories required relocating. Ekstensive made custom mounts for the ECM, ABS brain, air intake, wire loom, and more.
13. Many of the underhood accessories required relocating. Ekstensive made custom mounts f

14. One of the detail items that many trucks miss is the inner fenders. Ekstensive dressed our Ram with sheetmetal skins to make the area appear smooth when viewed from the outside. This extra touch added a nice, finished look to the fender area.
14. One of the detail items that many trucks miss is the inner fenders. Ekstensive dressed
15. Moving rearward, the transmission crossmember hung well below the frame, so it was removed and the mounting horns were cut off with an acetylene torch.
15. Moving rearward, the transmission crossmember hung well below the frame, so it was rem
16. Two plates were created from 1/4-inch steel and then drilled and threaded. These served as the new frame mounts.
16. Two plates were created from 1/4-inch steel and then drilled and threaded. These serve