FULLSIZE BRONCO OF THE YEAR CONTEST - 2017! VOTE HERE!!!!!! - Page 3 - Ford Bronco Forum
View Poll Results: Choose your favorite Fullsize Bronco of 2017!!!
Quader1 39 54.17%
remco 17 23.61%
greasemonger 5 6.94%
'89Bronco302 6 8.33%
cobrajoe 5 6.94%
Voters: 72. You may not vote on this poll

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post #41 of 216 (permalink) Old 11-09-2017, 01:07 PM
Erik
 
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So next for me was the one ton axle swap. Wish I would have went straight to this swap rather than the ttb lift. Found a kingpin dana 60 and 10.25 for cheap and not too far from home. Shortly after I bought the axles.



This turned out to be a drawn out project.
Most stuff is documented in my sas thread. http://www.fullsizebronco.com/forum/...k%3Ddeath.html
Where I never finished it..
I bought some 5.13 gears for the axles, superlift coil springs, f250 shock mounts, cage arms, etc..

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post #42 of 216 (permalink) Old 11-09-2017, 01:24 PM
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The last time the ttb was in there..

Every sas needs one of these pictures.

New coil buckets in place of the old.

Mocked into place.

And back on its own weight.

The upper trackbar bracket together.

Mocking up the sterling.

New tires.

Time to break out the cutoff wheel.



Progress..

My battery tray.

The sas snowballed into more. So next was the cage and bumpers.

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post #43 of 216 (permalink) Old 11-09-2017, 02:02 PM
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If possible, could you detail that trackbar mount and how you have it set up. My nerves have me wanting one if Im going to continue driving this thing to wheeling spots, but still wants at least some flex




dr jekyll: 86 built 302,30 over, carbed, 4" lift on 35s...mr hyde: 88 302 LS SAS, both ends locked, hydro assist, 5.13s, on 38 toyos
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post #44 of 216 (permalink) Old 11-09-2017, 07:39 PM
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Hereís what I have in the sas folder about the trackbar mount. Started with the bracket to the right and cut off part of it (the bracket on the left is welded to my axle).

Here Iím mocking it up on another piece of metal.

Came up with this first.

Then I added more gussets and the brace that bolts to the engine crossmember.

Bolted in place (ignore the old rusty pitman arm that is now gone.

I definitely overkilled the size of my trackbar.
Random progress pic.

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post #45 of 216 (permalink) Old 11-09-2017, 08:34 PM
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How Awesome is this years FOTY Competition???

The Competitors are Sharing "Tech Tips" with each other During their Battle for F.O.T.Y.

Me thinks this Epitomizes our "Full Size Bronco Brotherhood".

RIGHT ON....

**End of Hijack. **

Dragon

Do You want to Participate in the 2019 Moab "Full Size Bronco Invasion" ??? Looky Here, https://www.fullsizebronco.com/forum...on-2019-a.html

Here is the "Planning & Info Only Link", https://www.fullsizebronco.com/forum...info-only.html
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post #46 of 216 (permalink) Old 11-09-2017, 09:44 PM
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OK,enough snow talk; back to the build. I had a 3" body lift for a late 80's Bronco that someone gave me at least ten years ago, sitting on the shelf at the shop. I had been trying to decide what to do for steering clearance and figured maybe I'd put it use. I really didn't want to go 3" as I figured it'd be too much. ( I hate the air gap between the body & chassis and the bumper spacing). So for two solid nights (I work on the truck after work) I managed to remove all the body bolts from the truck, cut all the spacers down to 2" and run a die over all the bolts too make up the difference. The rear roll pan covers the chassis gap really good and I think I'll mount some tow hooks under the rear frame rail. Up front I plan on building a bumper with tapered end to help the turning radius and I'll extend the height to cover the gap between the body & chassis. Here's where I ended up:







I stopped by my buddies Boneyard and scored a pair of these:



I wasn't really happy with the frame rails showing after I did the body lift, so I thought they might fill the void a little better.

I also scored this freebie from my buddies boneyard when I liberated the F150 tow hooks last week:




It's out of an Excursion but the color is wrong, so when I went to buy my red paint, I had a radio bezel from a spare dash that I brought with me to Lowes to try and match the color. I found this;



I sprayed the cupholder from the console ( it was black, like the extra one I grabbed to the far right bottom of the pic ) and it seems to match up pretty good with the radio trim piece. It's far enough away from everything else to be close enough. I think the wood grain will tie in nice with the Eddie Bauer wood trim too.

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When I was fourteen years old, I was amazed at how unintelligent my father was. By the time I turned twenty-one, I was astounded at how much he had learned in the last seven years



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post #47 of 216 (permalink) Old 11-09-2017, 09:49 PM
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So here's the new piece on the bench:



This thing needed some serious cleaning:



Here we are dissambled:







Cleaned and sanded:



A couple of quick coats to see the color difference:



For those of you who haven't done this before; the entire top piece is wood grained ( you can see the nicks in the cover are brown ) and not removable. They simply paint the surround the color of the interior, so you have to mask it off, scuff, and paint:



Here's the factory console:



...and here's the Excursion console; I think it's a better match to the Eddie Bauer wood grain trim:



I might take a grey scuff pad to it or maybe some compound on a rag to dull it out.

When I was fourteen years old, I was amazed at how unintelligent my father was. By the time I turned twenty-one, I was astounded at how much he had learned in the last seven years



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post #48 of 216 (permalink) Old 11-10-2017, 08:59 AM
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I pulled the shocks and dropped the transfer case and cross-member down. Scuffed and cleaned them and gave them a fresh coat of paint to try and add some color to the truck; these things are huge!!! Ride height is at 28" length. Fully extended is 34" and change. I had to hold my phone behind my head to get them in frame, lol.




Installed;













I took the buffer to the passenger side to try and remove the "Nantucket Pinstriping" ...as you can see in the pic:




When I was fourteen years old, I was amazed at how unintelligent my father was. By the time I turned twenty-one, I was astounded at how much he had learned in the last seven years



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post #49 of 216 (permalink) Old 11-10-2017, 10:26 AM Thread Starter
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I forgot to mention before I installed the Carpet that I completely re-wired the BKO with an AAW kit. I made it easy by separating sections and taping them off.

Here are some pics laid out:






I didn’t want to go with the Bench seat that came with the BKO and wanted to go with OEM Buckets so I picked these up from Driven 4X4 with brackets:









I sanded and painted up the brackets, and installed them. I also installed an amp for the stereo system under each of them 1 for the Bass, and a 4 channel for the mids and tweets. (can’t find pics for the 4 channel)







One of the most asked about things on my BKO and how I met @itwasFREE!!!! (the first thing he asked about) was the Center consul. I made it from scratch and am very proud of it. It took me about a month to make as I ended up making it twice. I wanted something different and also wanted it to do a lot.
It’s a Bass box, cup holder for front and rear, has 2 storage compartments, Cig lighter power points on both sides, arm rest at just the right height , and all the corners I tried to make bull nose to match the truck as much as possible.

I started with cardboard to get down the shape of the floor. Keep in mind I did the width without having the seats in my possession as they were off to get upholstered.

I used 4X8 PVC sheets to make the center consul (other than the base box)

Here is some mocking it up along the way:








The progress up until upholstery :











And then upholstered :












Pretty big post now so I’ll show them installed later

Thank you for looking

Last edited by Quader1; 11-10-2017 at 10:32 AM.
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post #50 of 216 (permalink) Old 11-10-2017, 10:43 AM Thread Starter
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Back in Sedona with two other BKOís There was a staircase I wasnít willing to go up. 1) I didnít have lockers yet at the time and 2) I was still very green at wheeling. I did go up it last month but more on that later.

Here it is from the top looking down:




While we were at the bottom waiting the traffic for itwasFREE to go up this there was a quad coming down about a quarter of the way down and got too scared to come down. So we climbed up and helped him down:






I do have GoPro, and Cell phone video of me going up it last month (on the Honeymoon Run) that I will show later in the competition.


Here is some more pics of the BKO in the beautiful Sedona Arizona :























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post #51 of 216 (permalink) Old 11-10-2017, 10:52 AM Thread Starter
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Here is a video slideshow that is under 2 minutes for your BKO Porn pleasure :



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post #52 of 216 (permalink) Old 11-12-2017, 09:48 AM Thread Starter
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I was able to use the PVC to make panels for the headliner, and rear quarter panels. It was very easy to cut, and heat up and form the roof.















I sent those off the upholstery and I started putting the interior together










Here is the finished headliner





The Seats and center consul installed:


















Here are a few misc pics from a trail run up to a place called Workman Canyon. Great drive and is up by Roosevelt lake. This was a beautiful run:













Thank you for looking
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post #53 of 216 (permalink) Old 11-12-2017, 11:59 AM
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Thatís some clean interior work! Looks sweet - and I have similar plans for a console - never considered PVC. Nice work!
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Don't be fooled by the name,
1996 XL with 5.8L/E4OD/BW1356,
4.56 gears with lockers

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post #54 of 216 (permalink) Old 11-12-2017, 06:16 PM
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I had been contemplating the front bumper design for awhile and came up with a plan; I needed something that would give me steering clearance as well as add 2" to hide the body lift gap. Naturally, I went seem my buddy and asked him if he was willing to give it a whirl. He agreed and liked my idea, so we ordered up the materials. We bent up a couple of test pieces from some scrap and ran back to my shop to test fit. Our second attempt was better than what I had envisioned so we headed back to his shop and started cutting and bending.

Here's a few quick step by step pics:

His our shiny sheet of 1/4" material:



next, we sheared it up to size:



Now the first bend:



A quick run back to my shop for a test fit:





...and then back to the shop to bend up the rest:



We made some more cuts and tacked the pieces together:





...then back to my shop for a test fit:




I'm really happy with the way this coming out.

A few more cuts and a few more tacks.....





...and you guessed it back to my shop for another test fit:




Now the hard part; the transition down the sides to match up with the fender flares and wheel opening. Also have to cut some holes and weld in some pipe for lights, to break it up a little. I was concerned that it may get too bulky trying to hide the body lift but, I'm pleased so far. I am extremely fortunate to have someone that has the equipment and talent to help me with this.



and little more work on the bumper, getting closer:








When I was fourteen years old, I was amazed at how unintelligent my father was. By the time I turned twenty-one, I was astounded at how much he had learned in the last seven years



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post #55 of 216 (permalink) Old 11-12-2017, 06:18 PM
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Next thing we did was Bologna slice some 4" pipe for fog lights:



Then transfer the hole over to the bumper face and cut them out with the plasma cutter:





Then we used the MIG gun to tack them in from the back side:





The view from the front; ready to TIG:





This kid can really weld:



Ready for the next step:



Then the next thing was to cut up some brackets and match the bumper holes and add some slots:




then weld in the sets of brackets;



Flip it around and blend the welds for the light holes:



then take the 1/4 round and a router to them:



and then back to my shop for a test fit:



really starting to look awesome! I am so glad that I was able to cover up the 2" gap from the body lift with the bumper and the rear roll pan



...now it's try and figure out how to make these ends look good and match the fender flares, but that's for another day....


When I was fourteen years old, I was amazed at how unintelligent my father was. By the time I turned twenty-one, I was astounded at how much he had learned in the last seven years



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post #56 of 216 (permalink) Old 11-13-2017, 05:30 AM
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Quote:
Originally Posted by '89Bronco302 View Post
Every sas needs one of these pictures.
I agree!


Quote:
Originally Posted by cobrajoe View Post


What does October look like?

Dam @Quader1 , you have your own website? Chevereto - Chevereto image hosting

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post #57 of 216 (permalink) Old 11-13-2017, 08:19 AM
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Next in my bronco saga was the bumpers and roll cage. During this time the sas was still not done. Mainly needed to finish shocks, brakes, and driveshafts. Scored a warn winch bumper and winch for cheap.

Ended up not using the warn bumper because it seemed flimsy. My buddy built this front bumper with free steel. He incorporated the winch mount from the warn bumper.


And here it is mounted. Both bumpers are welded directly to the frame. They easily allow me to use the hi lift jack with how their set up.


And the rear bumper.. Its tucked in as far as the tailgate so itís like a roll pan but beefy (You can see the new tailgate. I welded the window slot, key hole, and tailgate handle holes shut).

Some on the cage next since we did that around the same time.

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post #58 of 216 (permalink) Old 11-13-2017, 04:27 PM
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We took some measurements, made some cardboard templates, pulled it off and headed back to his shop.



Then we transferred the template onto the material and started bending:





Then fitted and tacked the pieces together:






Getting closer and getting late:



Back to my shop for a test fit:



(It looks wide, but the fender flares will cover a good portion )


Then trim for the wheel opening:



Looks like it will work, now back off and to his shop to cap the ends, finish welding and blend the welds.

Final cut and trim, and fab up some end caps:



Finish weld:







I think the radius finishes it off:









Ready for body work and paint!


When I was fourteen years old, I was amazed at how unintelligent my father was. By the time I turned twenty-one, I was astounded at how much he had learned in the last seven years



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post #59 of 216 (permalink) Old 11-13-2017, 06:13 PM Thread Starter
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Got the door panels all painted up with SEM Plastic spray. I also installed electric windows and door locks.











Then was the Stereo and speakers:













Thank you for looking
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post #60 of 216 (permalink) Old 11-13-2017, 06:31 PM Thread Starter
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Now time for some new Photos. Here is a few pics from a Meet N Greet we had at a place east of the valley called Bulldog Canyon.

After getting the driver side rear quarter bodywork fixed from my Moab trip almost a year to the day at Bulldog Canyon I tagged the Passenger side Rear Quarter. But overall this was a fun Trail run.











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