Hi Gary, I'm going to be looking at the fuel production first as this seems to be the most work and probably most difficult. If the fuel manufacturing pans out well, I know that I will be jonesing to get on the road asap haha , but I can easily see the value in trying my hand at a small scale set up to do a little learning and maybe some changes/refinements before going large scale. I do have a 20hp Kohler V Twin powered lawn tractor doing nothing :).
I am still collecting ideas on the net regarding design, but so far I am really liking Don Mannes design and his excellent results. I plan the bottom type tyure nozzle, probably made from castable ceramic, with everything else being 304 stainless as I like how J.O.O's stainless wood gasifier is holding up in a similar climate as I will be dealing with. I'm not sure how I will feed the unit yet (from divorced hopper). Packaging will be a concern, but won't be known how bad until I buy the vehicle everything is going into.
Did you ever figure out if the no start issue with your Ranger had anything to do with running chargas on an OBD2 vehicle?