Project "Farmhand" 1991 XLT - Ford Bronco Forum
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post #1 of 223 (permalink) Old 01-09-2014, 11:27 AM Thread Starter
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Project "Farmhand" 1991 XLT

Well, its been a year since I bought my 91' XLT and just realized that will all I've done to it, I should have a build thread on it. So this first post is just going to be all I've done to it in the past year.

I didn't really start out with any real direction in mind when I bought her. But my intent seems to be to turn her into the ultimate farm hand truck. I pretty much use her as a rolling shop.

When I first bought it:


She was very clean with I bought it. The only serious rust issue I had (still have actually) is the core support, passenger side is rusted through. I just need to get off my ass and get a donor one from the JY.


Anyways, the first thing I did was take it into the base hobby shop and change all the oils and filters and give her a real look over.
Replaced the radiator hose:

Why anyone would patch the hose instead of replacing it is beyond me.

Next, I fixed the tranny temp gauge the PO had installed. The temp sensor was just wired backwards, but the way the PO used a trailer light wiring harness just made me want to .


Next I pulled some roof bars off an explorer and mounted them to the shell as the start for a roof basket install, which I'm still working on.


I also picked up some tow points from an expedition in the JY and throw them on as well. I did have to trim the bumper a bit, but the fit is almost perfect now with no sag or tilt to the bumper.


I then began work on a custom forward center console. I kept the bucket console and just added to the front of it with some 1X12 pine boards. The console also houses some electronics for my lights and future projects, such as winch cutout and gauges.



Wired in the lights for front and rear.


Installed auxiliary reverse light.


I found this square tube grill at the JY on an F-150 and grabbed it up, since I have bad luck with breaking the plastic grills. Painted it up and mounted right in place. I've added newer lights since this pic was taken, but don't have any pics of them.



Finally got around to upgrading the exhaust over the summer. The original pipe where the two exhaust pipes connected had been broken and rewelded together and poorly at that.

I did have to tweak the new pipes a bit to make them fit, but it all worked out in the end. Sounds great and runs better!


I also had to replace the intake after the original developed a crack in the base. The old battery shelf since it had rusted through, and the passenger side window motor.

The last upgrade has been a tinkering project that turned into a nightmare. It started out as a simple axle seal replacement on the rear passenger wheel. Well, when I went to remove the axle, the screw that holds the spider gear shaft in the differential had broken off and could not be drilled out or removed. So I had to go get a new diff housing, but I guess I screwed up the swap, since the gears were grinding. Not much, but just barely noticeable to me. So I finally decided I'd had enough, went to the JY to get a "new" ring and pinion gear and redo the whole job. I struck gold however and the donor truck had a limited slip diff in it. So I decided to just swap out the gears and the diff housing as one. Saved me a buttload of trouble with swapping out the ring gear. Anyways, new bushings, bearings and everything. I was not gonna let this one get screwed up. Got it shimmed just right, within specs and now it runs like new. Love the way the limited slip feels on the snow.
B-man likes this.

1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #2 of 223 (permalink) Old 01-09-2014, 11:37 AM Thread Starter
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Okay. That was 2013 in a nutshell. This is what I have planned for 2014 and beyond so far.

Rear disk brake conversion
cold air intake Done(ish)
new tires (if the old ones wear out) DONE
new tow bar (the old one has issues from a bad install by the PO)
hidden bumper winch DONE
finish roof basket install DONE
more lights ( you can never have too many)
Auxiliary battery (for winch mainly) DONE
3G alternator DONE
seat covers from Coverking. Just waiting for them to arrive. DONE and DONE

What I'm thinking about right now:
LP or CNG injection (for towing)
roof ladder
Roof basket toolbox
Replace the door liners with sheet metal for cleaner look (Mine are cracked and broken anyways. The inside handle on the drivers side is falling apart.)
CB radio DONE
Snorkel (My home county floods all the time.)
New carpet (that's a ways down the road though)

1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand

Last edited by AFBronco235; 05-19-2019 at 11:27 PM.
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post #3 of 223 (permalink) Old 01-13-2014, 07:30 AM
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So far so good! Like the console idea. Might steal that from you. Planned on doing something similiar and just covering it with carpet.

'93 - Eddie Bauer 5.8 - 4" lift an other goodies!

-'96 Ranger 4cyl 4x4 almost 300k (just wont die!)
-'85 Mercury capri 5.0 RS - built nicely - summer toy.
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post #4 of 223 (permalink) Old 01-14-2014, 11:11 AM
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X2 on the console. My pile has a front bench. a console like that could be cup holders and general storage for me. Thanks for the idea.

91 Bronco/ 5.0 from a 96 F150/E4OD/OpenTTB/Open 8.8. 163k.
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post #5 of 223 (permalink) Old 01-15-2014, 12:47 AM Thread Starter
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Just pulled the trigger on this spotlight I saw on EBAY today. I can't wait to get it. Now all I need is the mounting bracket for it.
Made by UNITY MFG. CO. CHICAGO USA MODEL. Anybody know what compatible mounting bracket I need to get?
Attached Images
File Type: jpg Spotlight.jpg (147.0 KB, 2577 views)

1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #6 of 223 (permalink) Old 01-17-2014, 02:20 AM Thread Starter
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Okay, so a quick update. I've shelved the rear disk brake upgrade for now, since it seems I'm better off without it. Instead, I've begun working on my auxiliary battery install in preparation for the winch install I hope to do over the summer.

So far, I've gotten an aux. battery tray out of an old F-250 diesel, with the washer and coolant reservoirs included so I don't want to mess around with moving the stock reservoirs. I've also just purchased a 3G 150 amp alt to keep both my batteries charged. Now I just need to pick out a wiring kit. I'm thinking of going with the isolator with a three-way switch.


1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #7 of 223 (permalink) Old 01-18-2014, 02:28 PM Thread Starter
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Auxiliary Battery Tray install

Got around to installing my auxiliary battery tray today.

Step #1: Remove washer fluid and coolant reservoirs and mounting brackets along with the stock air filter box. (Note: I will be replacing the stock filter at a later date with a K&N cone filter.)


Step #2: Install mounting bracket to core support. No drilling required.

Step #3: Install base plates for battery. This is a direct bolt in tray from an F-250 so its really easy. Just make sure that you keep the original mounting hardware from the donor truck.

Step #4: Install the donor reservoirs in the new battery tray frame. When you remove the washer reservoir, make sure you grab the washer pump plug with as much of the wire as you can get. The bronco plug will not have enough wire to reach the new pump location so you'll need to cut and splice in the donor plug. You can get away with splicing in new wire, but its easier to just use the donor truck wiring.

Step #5: Move on to installing battery and wiring.
Attached Images
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1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #8 of 223 (permalink) Old 01-18-2014, 02:34 PM Thread Starter
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Additional pictures.

Until I get the K&N filter to replace the stock filter, I'm just leaving the stock filter in the battery tray. I did have to remove the intake from the core support, but I plan on doing something to replace it later on.
Attached Images
File Type: jpg 2014-01-18_11-40-27_662.jpg (126.8 KB, 2392 views)
File Type: jpg 2014-01-18_11-49-44_177.jpg (124.6 KB, 2376 views)
File Type: jpg 2014-01-18_12-00-54_452.jpg (137.6 KB, 8361 views)

1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #9 of 223 (permalink) Old 01-18-2014, 09:44 PM
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very nice so far. The custom forward console is well done.

'90 Eddie Bauer 302 5.0 >250k, class E, Stock wheels (if it ain't broke...) rebuilt under hood (oem). HD rotors. R-134A conversion. Flowmaster and 3" single chamber. Custom fishing pole rack. 145k '96 e4oD upgrade. 33" BFG A/T. Modern Am/FM/Bt/CD/USB. 1500w amp/ sub combo. Custom Roof rack. OE spare tire carrier modified to hold stuff. Spot/flood light. Fog lights. Trail cam mount. Check out my build thread...
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post #10 of 223 (permalink) Old 01-18-2014, 09:55 PM
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Looks good so far, I picked up a spot light just like yours at the jy the other day, just need to figure out where to place it.
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post #11 of 223 (permalink) Old 01-19-2014, 03:56 PM Thread Starter
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Its time to go with a little luxury. I picked up this roof console from a Navigator at the PAP yard this morning. I'm removing the climate controls and digital screen and replacing them with gauge clusters. At least two of them will be for my dual batteries. I'm also replacing the stock rocker switches, since they won't fit with the install. I'm not sure what I'll replace them with. Maybe an internal winch control switch?
Attached Images
File Type: jpg 2014-01-19_13-06-21_771.jpg (89.8 KB, 2362 views)
File Type: jpg 2014-01-19_14-09-15_419.jpg (114.2 KB, 2355 views)

1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #12 of 223 (permalink) Old 01-20-2014, 03:27 PM Thread Starter
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A little more luxury. I scored big time at the JY today. All I was going for was a pushbutton switch and mounting plate for the above roof console and light. I found that, and this as well! Now to figure out how to wire it all up. Should be fun on camping trips with the GF. Oh, and find a DVD player to go with it. The one in the donor van I pulled it out of was covered in something unidentifiable.
Attached Images
File Type: jpg IMG_0380.JPG (159.9 KB, 7577 views)
File Type: jpg IMG_0384.JPG (77.8 KB, 2820 views)

1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #13 of 223 (permalink) Old 01-22-2014, 11:36 AM Thread Starter
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Lookey what came in the mail today!!!


A remaned 150 amp 3G alternator and the spotlight with mounting hardware. I'm going to be busy this weekend!
Attached Images
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1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #14 of 223 (permalink) Old 01-22-2014, 01:29 PM
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following, looking cool
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post #15 of 223 (permalink) Old 01-22-2014, 05:46 PM
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Have fun man.

'90 Eddie Bauer 302 5.0 >250k, class E, Stock wheels (if it ain't broke...) rebuilt under hood (oem). HD rotors. R-134A conversion. Flowmaster and 3" single chamber. Custom fishing pole rack. 145k '96 e4oD upgrade. 33" BFG A/T. Modern Am/FM/Bt/CD/USB. 1500w amp/ sub combo. Custom Roof rack. OE spare tire carrier modified to hold stuff. Spot/flood light. Fog lights. Trail cam mount. Check out my build thread...
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post #16 of 223 (permalink) Old 01-23-2014, 01:55 PM Thread Starter
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Got the battery Isolator!
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File Type: jpg IMG_0392.JPG (188.2 KB, 2243 views)

1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #17 of 223 (permalink) Old 01-25-2014, 04:48 PM Thread Starter
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Got the spotlight and air intake done.

The spotlight was pretty easy. The instructions from unity on installing the bracket were easy to follow and well written. Went in easy. I just need to chase down some electrical gremlins now in the light itself. It will turn on, but if I try turning or moving it, it goes out. Sometimes it works, sometimes it doesn't. I'm thinking all the contacts just need cleaned and regreesed, so I'll be doing that tomorrow. And as you can see, I did have a minor oops moment with my transmission temp gage. All well, I got it fixed so no worries.

I also finished 2-into-1 intake. Went to the junkyard to pick up the 2-1 adapter, the store for a 3 inch exhaust couple pipe and the filter, so my total cost for this is just under $35. K&N systems would go for around $200 for the same thing and it probably wouldn't fit my application. I do need to fabricate a mounting bracket of some kind, but that's where the exhaust pipe comes in.

Okay, I first removed all the old intake stuff but saved the two rubber ducts from the filter box to the intake. I then laid out how I wanted the filter and ducting to go. I placed the filter next to the brake master cylinder and routed the 3 inch duct under it. I then mocked up the two rubber hose intakes, measures where they would meet up with the adapter and cut them to size. A couple of hose clamps and I was in business. However, the 3 inch duct did not mate up with the filter I had chosen. This is where the 3 inch exhaust pipe comes in. I used it to connect the ducting to the filter. Clamped it all down and viola, a $200 intake for $35.
Attached Images
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File Type: jpg 2014-01-25_13-58-57_571.jpg (130.1 KB, 8081 views)

1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #18 of 223 (permalink) Old 01-25-2014, 06:01 PM
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What is the wattage on the spot light? Looks pretty cool. Any pics of the control knob inside?

TT-RACING
EX #56 - 2010 Kawasaki ZX-10R.
Thanks to:Inglis Cycle, Pro6 Cycle, Armour Bodies, PBI Sprockets, Dunlop Motorcycle, Blue Streak Racing, VnM Sportgear
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post #19 of 223 (permalink) Old 01-25-2014, 08:19 PM Thread Starter
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Reclocked my new Alt after I tried to install it and discovered it was clocked wrong.
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1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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post #20 of 223 (permalink) Old 01-25-2014, 08:21 PM Thread Starter
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The rest of the reclocking.
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1991 Bronco w/ 5.0L V8, Auto w/ E40D trans, factory spare tire rack, factory limited slip diff, dual batteries, custom air intake, 8K lb. winch, tactical seat covers, drop down TV w/ CD/DVD player, 31's on stock suspension, roof baskets, new injectors, rear bumper w/ tire rack, 33" Goodyear Wranglers, 2" suspension lift.

To Do List: paint,
My BKO build: Project Farmhand
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