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Old 08-16-2010, 03:01 AM   #61
American Thunder
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Bronco Info: 1978 Bronco 9" lift, 35s, Cummins power
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Originally Posted by seawalkersee View Post
Strange...I kind of hate you right now because your setup is what I wanted to build. BUT...since I have my 84 and could not pick up a cummins for under $2k (core) and then needed to get my stuff to add it to the setup so it would EASILY be $4k. I pikced up my 6.9 for $400 and a set of headers. It was complete from the intake to the clutch and bell housing with about 3' of exhaust. So...with about $100 bux in spare parts, a new high torque starter, $100ish on injectors, (and about $500 in other misc stuff that adds up quick), a torque grind cam, I was good to go and drove it on 100% oil for about 2-3K miles. Seriously about $50 in diesel for the entire time.

SWS

That sounds like a nice setup!
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 08-16-2010, 11:18 AM   #62
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Bronco Info: 84 FSB with a 6.9 diesel/zf 5, supercharger, and 33s.
Ehhhhhh....Kind of rusty as luck would have it. But when it was running the first time, I was dogging the heck out of it and still knocking down an easy 18mpg. Soon the lift and SAS will come, but I want to get the supercharger on it while I can still work on it without a step ladder.

SWS
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Old 08-18-2010, 01:24 PM   #63
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At some point, I will assemble a complete roadside kit for the truck, that contains every tool I would need for any minor repair like the lift pump, fuel lines, s-belt, etc. I plan to use this beasty for long distance runs once I get everything in order. It's also really nice to have tools if you run across another guy who's in trouble alongside the road.

Throughout this project, whenever it was possible, I wanted to use parts that were readily available at any local auto store or junkyard. Who wants to be stuck during a trip a few hundred miles from home with a broken truck and some aftermarket part that takes a few days minimum to get to you??

An example of this line of reasoning is my charging system; I used the original stock Dodge/Cummins 135amp alternator, and a stock 1978 Ford voltage regulator. They work together quite well, plus, a new alternator is $90 and a regulator is $20, both available at Napa. What made the hook up easy, was that a lot of Dodge guys are running a Ford regulator because on the Dodge, the regulator is built into the main computer, which isn't cheap. So when their regulator blows out, they simply wire in a Ford regulator for $20, and they're back in business. So finding the information on a similar hook up was easy.
This is the diagram I made:

It charges in the high 13s. 13.6 if I recall? And having the 135amp Cummins alternator is a big improvement over the original '78 unit.
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 08-21-2010, 12:24 PM   #64
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Thank you very much for the compliments, it was a lot of work and a lot of saving up for parts.

Ah yes, the paint.. hmmm. I'm a big battleship fan, especially the Iowa-class American BBs. The USS Missouri and USS Iowa wore an awesome gray and black camo scheme for a time during WWII, and once I get the body rust repaired on my Bronco, it's getting a coat of satin finish BB camo.
It's about as cheap as you could get, easily repaired if scratched, and it will be a tribute to our armed forces.

This is what the camo will look like.

Since the truck will have the battleship theme, I designed this decal for the rear window:


I don't like blending in with the crowd.

so kinda like Das Bronco from Trucks?


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Old 08-21-2010, 01:06 PM   #65
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That Bronc looks pretty neat, I'm not sure which KM camo pattern it is.
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 08-21-2010, 01:43 PM   #66
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Bronco Info: 79Bko:400,c6,np205,d44,9",35"tires.
Dazzle Camouflage

this is what das bronco paint scheme was based on.
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Old 09-01-2010, 03:34 PM   #67
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Awesome project! I don't have the skills you do (or the equipment), so I'll probably have FordCummins do the swap for me. When I get the money, that is.

I'm a bit shocked at the weight. When I moved to Washington, I had to have my bone-stock '79 weighed at a certified scale, and it showed 5,960 pounds. Does that square with anyone elses experience?
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Old 09-01-2010, 03:58 PM   #68
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Thanks!

As for the weight, by comparison, my '83 Bronc with a 300 and 5-speed(that wasn't a fun swap) weighed a hair over 4600, but that had a lot of body rot, too. My buddy's '67 F250 4x4 longbed with a 390 and 4 speed weighed exactly 5150 lbs.
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 09-01-2010, 09:41 PM   #69
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I wish I had a few more Bronco's.

SWS
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Old 09-02-2010, 10:50 AM   #70
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I'm going to have to look for all those gold bars that must be under my seats, I guess.
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Old 09-30-2010, 02:36 PM   #71
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 09-30-2010, 02:42 PM   #72
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I relocated the battery to the driver side, in order to make room for this big universal K&N air filter. I welded up a sheet metal bracket to secure it, and bolted it down using the factory integral nuts, which were formally used for the original battery tray. The universal filter has this convenient mounting stud in the top, so it made things easier. You may have noticed a pattern of my using factory integral pieces and mounting holes, as I like doing that whenever possible. I used some scraps of exhaust pipe I had around the shop, and some of the original Dodge/Cummins flexible rubber intake hose to hook it up. This whole thing only cost me 65 bucks.

I'm still waiting for the back-ordered all stainless steel battery tray coming from Summit Racing. For now, I just have a strap holding the battery in place. Once I get the new ss tray in place, some pics will follow.
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 09-30-2010, 02:56 PM   #73
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Great build. I've got a 79 Bronco with 3.00's (stock) in the front reverse D44 so they are out there.
If I could find a set of 3.00s for the reverse cut D44 front, it would change my whole game plan. I'd build up the D44 for strength and better brakes, (http://broncograveyard.com/bronco/i-...u-joints-.html) rather than upgrade to a D60, which I believe is only available with 3.54 and higher gearing..
3.00s would make me VERY happy. If you decided to sell the ring and pinion from that truck let me know!

With torque being so high at 1600 rpm, Ideally, I would want the motor at 1600 RPM when cruising at 55 mph for best fuel mileage.

Using this online speed calculator, (http://www.mustangii.net/topspeed.asp) I can run some tests: (results rounded)

3.50 gears + 35" tires + 1:1 trans @ 55 mph = 1900 RPM.
3.00 gears + 35" tires + 1:1 trans @ 55 mph = 1600 RPM.
I'm currently looking for a good used set of tires that aren't super aggressive, since this is my daily driver. I'd take anything between 35" and 40" I guess. Though I'd prefer closer to 35".

3.50 gears + 40" tires + 1:1 trans @ 55 mph = 1600 RPM.
Though the 40" tires with 3.50 gears would put my motor at the desired rpm for best fuel mileage, the added drag of the wider and heavier tires may negate any gains.
I average 20 mpg now, but I bet with 3.00 gears it would increase to 22-24, plus the motor would rev less, therefore, last even longer.
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 09-30-2010, 03:23 PM   #74
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Maybe i missed it but, where are the sound clips man??? i want to hear this thing in action. I think these diesel swaps are awesome and would love to do one. Sadly, i lack a lot of skills to do it.
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Old 09-30-2010, 03:44 PM   #75
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How about video clips? (edit: I already posted these before, but.. what the hey, here they are again.. )


The Cummins Bronco's first breath of life..



Quick run down the road, accelerating 28-48 mph.
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 10-01-2010, 01:11 AM   #76
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Bronco Info: 1979 built 400 spooled 4.56's comp cut boggers. 84 economizer, 300 4 spd 6" lift
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Originally Posted by American Thunder View Post
If I could find a set of 3.00s for the reverse cut D44 front, it would change my whole game plan. I'd build up the D44 for strength and better brakes, (http://broncograveyard.com/bronco/i-...u-joints-.html) rather than upgrade to a D60, which I believe is only available with 3.54 and higher gearing..
3.00s would make me VERY happy. If you decided to sell the ring and pinion from that truck let me know!

With torque being so high at 1600 rpm, Ideally, I would want the motor at 1600 RPM when cruising at 55 mph for best fuel mileage.

Using this online speed calculator, (http://www.mustangii.net/topspeed.asp) I can run some tests: (results rounded)

3.50 gears + 35" tires + 1:1 trans @ 55 mph = 1900 RPM.
3.00 gears + 35" tires + 1:1 trans @ 55 mph = 1600 RPM.
I'm currently looking for a good used set of tires that aren't super aggressive, since this is my daily driver. I'd take anything between 35" and 40" I guess. Though I'd prefer closer to 35".

3.50 gears + 40" tires + 1:1 trans @ 55 mph = 1600 RPM.
Though the 40" tires with 3.50 gears would put my motor at the desired rpm for best fuel mileage, the added drag of the wider and heavier tires may negate any gains.
I average 20 mpg now, but I bet with 3.00 gears it would increase to 22-24, plus the motor would rev less, therefore, last even longer.
There is a Dana 61 that uses 3.07 gears. Not sure what all they put them in, pretty sure early cummins trucks without overdrive.
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Old 10-01-2010, 01:56 AM   #77
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Oh yeah, I see that.. Very cool! I did a check and new 3.07 ring and pinion sets are available for the D61.. wow

I found this on a search:

What's the deal with the Dana 61?

With mileage and emissions concerns rising, at some point Dodge and / or Ford decided they wanted to be able to offer gears higher than the current highest ratio of 3.54 available in the D60. However, because of the design of the D60 the pinion head could not be made big enough to achieve a higher ratio. Hence, the birth of the Dana 61, which has a different casting that moves the pinion over 0.25"-0.437" (conflicting reports) - this allowed for a 3.07 axle ratio. The Dana 61 also uses 3.5" axle tubes. Other than that, it is very similar to the Dana 60. The Dana 61 was common in Dodge front ends and Ford van rears.


Thanks for the info!
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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Old 10-01-2010, 02:28 AM   #78
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Your above theories on mpg/gearing are what I built my rig around. 3.73 + 40"tires( I guess to make it a math problem, since a 39" tire is 28% than a 31.7" tire... it should be :3.73 x .72 x 1:1 final drive gearing = 3.04 final drive, equals 31.xxxx mph per 1k rpm.
2k should be flirting with 65mph. Our torque peaks are quite similar, if anything I am at 85% torque by 1400. I am just scared that now I have gone NA, I will not have the hp/tq to overcome the parasitic loss of the drivetrain/Co-ED
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Old 10-01-2010, 04:20 AM   #79
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Can I drop my bronco and a cummins by ur house and you can do the work for me?

Ive been wanting to do this forever!

Nice job man!
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Old 10-01-2010, 11:34 AM   #80
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Can I drop my bronco and a cummins by ur house and you can do the work for me?

Ive been wanting to do this forever!

Nice job man!
Actually, yes, I probably could. You're only about an hour away.
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1978 Bronco 9" lift on 35s, with 1991 Cummins 6BT swap, Denny T fuel pin, pump mods, 3200 gov. spring, Trac-Loc front diff, C6 built by Dynamic Transmissions with billet 1200 rpm converter, 4" exhaust, no muffler. GOT TORQUE?
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