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Old 10-12-2009, 02:40 PM   #1
ScreaminZ
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78 Rock Crawler

Guess I'll give this build thread thing a shot.

I started out building an '86 Bronco and while out having some fun, I managed to break the frame behind the steering box. I decided that was the time for a SAS. I started mocking it up and figured out how difficult it was going to be to keep a low COG with that stock TTB crossmember. Long story short, I started looking for a '78-'79 frame to put under the Bronco. I found a '78 for sale for $300 and had it delivered to the shop. After taking a good look at it, I decided I liked this one much better than my '86, so all the parts are going into this one instead.

What I was told was that the rear axle was making noise and the PO removed the shafts and chunk to replace them and never got around to it. Here it is as it was delivered:





Then I bolted my Dana 70 under the rear of it and set it up on jackstands to get that puny little Dana 44 out from underneath the front:



I'm currently tearing down the Dana 44 from the front and plan to use the wedges from it to mount my Dana 60 under this thing. As for drivetrain, I'm still undecided. May throw the EFI drivetrain from my '86 in there or I may just go propane on the 400 that's already in there. Either way, the carb has to go as they don't seem to care much for extreme angles.

As soon as I get the front axle mounted, I plan to do a little cutting to make room for these:



Hopefully I can actually keep this thread updated as I go. If I ever forget, please feel free to remind me!
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Old 10-12-2009, 10:15 PM   #2
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good!!! im gonna make a similar build, im buying pieces little by little, so its nice to see another broncos whit same purpose!!!! what size are taht tires!!! you gonna put ram assistance??? put your specs!!! saludos!!!
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Old 10-12-2009, 11:13 PM   #3
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I really like those wheels.
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Old 10-12-2009, 11:51 PM   #4
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If that's the stock Motorcraft 2150 carb, it's really easy to make it run great on extreme angles.
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Old 10-13-2009, 09:32 AM   #5
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what size are taht tires!!! you gonna put ram assistance??? put your specs!!! saludos!!!
The tires are 15/42-17 Interco Super Swamper SX-II's on 17x9.75 Raceline Monster II beadlocks. All those bolts are a pain to get torqued down!

For steering, I plan to go full hydro since this rig will probably never see the street again. I've already got my front Dana 60 stripped down and the tubes cleared of all brackets. Also have all new bearings, brakes, detroit locker, 5.13's, high steer arms, etc. all sitting here ready to go.
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Old 10-13-2009, 09:33 AM   #6
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If that's the stock Motorcraft 2150 carb, it's really easy to make it run great on extreme angles.
Some previous owner has swapped the intake and carb for Edelbrock Performer. I really don't know anything about these and how well they do off-road. I know there are some things that can be done, but nothing appears to have been done to these. Anybody have any experience with these carbs and/or have any good links with info?
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Old 10-13-2009, 09:37 AM   #7
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Well, I'm running into some minor difficulties on getting the Dana 60 into this thing. I tore down the Dana 44 front end and was planning on boring out the center of the wedges to fit the dana 60, like these guys did here:

http://www.jantz4x4.com/projects/downs/downs1.html

I don't care to do the wristed setup, but just figured I could bore out the center, cut them in half, and then weld them onto my D60. The machinist guy here at work says he doesn't have the equipment here at work to be able to bore that out like that. I'm starting to think that maybe I need to break down and buy the weld-on wedges from Duff or JBG. Will post whatever I end up deciding to do.
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Old 10-13-2009, 09:37 AM   #8
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Well, I'm running into some minor difficulties on getting the Dana 60 into this thing. I tore down the Dana 44 front end and was planning on boring out the center of the wedges to fit the dana 60, like these guys did here:

http://www.jantz4x4.com/projects/downs/downs1.html

I don't care to do the wristed setup, but just figured I could bore out the center, cut them in half, and then weld them onto my D60. The machinist guy here at work says he doesn't have the equipment here at work to be able to bore that out like that. I'm starting to think that maybe I need to break down and buy the weld-on wedges from Duff or JBG. Will post whatever I end up deciding to do.
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I got all my multiple forms of lube all lined up and will give them a shot this afternoon! Its gonna be fun.
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Old 10-13-2009, 12:20 PM   #9
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Sounds like this thing is going to be sweet.

As for the carb, Im running a Offroad holley truck avenger, So far does well on hills. But I need an electric fuel pump because my engine wants more gas then the mechanical pump can pump.
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Old 10-13-2009, 02:24 PM   #10
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Sounds like this thing is going to be sweet.

As for the carb, Im running a Offroad holley truck avenger, So far does well on hills. But I need an electric fuel pump because my engine wants more gas then the mechanical pump can pump.
Good to know. I'll keep that in mind.

For the Dana 60 swap, I was out there looking everything over with the bossman and going over the different options. He's trying to talk me into doing a triangulated 4-link. Guess I'm going to pull the front clip and lift the 60 up into place to look everything over a little better. This could get interesting...
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I got all my multiple forms of lube all lined up and will give them a shot this afternoon! Its gonna be fun.
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Old 10-13-2009, 03:24 PM   #11
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those tires look awsome. I probably would have opted for some Stauns internal beadlocks vs the wheels but otherwise this is a great build
what is your weight goal and how do you plan on reducing the weight?
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Old 10-13-2009, 03:47 PM   #12
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those tires look awsome. I probably would have opted for some Stauns internal beadlocks vs the wheels but otherwise this is a great build
what is your weight goal and how do you plan on reducing the weight?
These wheels were cheap, and I needed some wheels anyway. I can't imagine the Stauns would have been any less trouble to deal with than the beadlock bolts. Also, I kinda like the look of all those shiny gold bolts!

As for weight goal, I'll let you know when it's done! Honestly, I have no idea what these things weigh stock or where this one might end up. I do plan to add a full cage, all the way to the rear. I need to keep it fairly big since I need to keep the back seat for kids. Otherwise I'd chop it off behind the cab. I do plan to remove all unnecessary wiring, heat/ac equipment, etc. Also may eventually have to do something about that gawdawful heavy NP205. We'll see how it all ends up. It will definitely be a work in progress. First step: get that Dana 60 under there and get it on the trail.
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Old 10-14-2009, 10:50 PM   #13
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What kind of D60 haves you??? the wedges im buy a pair of JBG, my plan its normal triangulated, track bar, and long radius arms whit Johny joints!! and for the fuel sistem, im gonna try to go fuel injected!! sorry for my bad english im from mexico!! Saludos!
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Old 10-14-2009, 11:34 PM   #14
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What kind of D60 haves you??? the wedges im buy a pair of JBG, my plan its normal triangulated, track bar, and long radius arms whit Johny joints!! and for the fuel sistem, im gonna try to go fuel injected!! sorry for my bad english im from mexico!! Saludos!
I've got a front Dana 60 from an 87 Ford Dana 60. It's got the really short driver's side tube that makes mounting anything difficult. I should have something decided as to what I'm going to do in the next few days.
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I got all my multiple forms of lube all lined up and will give them a shot this afternoon! Its gonna be fun.
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Old 10-15-2009, 11:13 PM   #15
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maybe whit that type of axle, you can look brackets in ballistic or maybe make your own barckets, to put a kind of long arms whit joints in boths ends of the long arms, im thinking in that option, one guy of austrlia has a build whit that type of axle, search in the site, good look!!!
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Old 10-16-2009, 09:17 AM   #16
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cant wait to see the finished product!
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Old 10-19-2009, 10:14 PM   #17
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Not too much of an update, but figured I'd post something to keep this thread going. The last few days I've spent some quality time tearing this ol' girl apart. Got the interior basically gutted, top removed, front clip removed, etc. The interior was pretty gross. The previous owner left several partial bags of dog food in the back with one of the windows on the top busted out. The dogfood got nice and moldy and I found maggots living under the carpet. Gross. Anyway, I hope to get my Dana 60 up to the shop in the next few days so I can jack it up into place and start figuring out how I'm going to mount it in there. Until then, here's a few pics.

bye-bye front clip and axle:




no more moldy interior:
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Old 10-19-2009, 10:34 PM   #18
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Are you ditching the front clip permanently?
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Old 10-19-2009, 10:36 PM   #19
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Nice work so far, can't wait to see the finished product
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Old 10-19-2009, 10:43 PM   #20
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Sounds like this thing is going to be sweet.

As for the carb, Im running a Offroad holley truck avenger, So far does well on hills. But I need an electric fuel pump because my engine wants more gas then the mechanical pump can pump.
thats the same setup i'm running. i can almost stand my truck on end and it will still run! Holley recommends about 7psi feed. my electric pump is running about 8-9 psi.
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