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Discussion Starter #1
*4/15/18 -- Editing this thread into my build thread*

This will be a slow moving build, as time and money allows.
Compared to many Broncos I see on here, my build will be fairly mild.

Goals
This is my daily driver, though I probably log less than 50 miles a week.
I want something that is great for general 4x4 fun (camping, mountain trails, etc)., but can handle whoops and the like in the desert, mild jumps at the dunes, etc.
Not an expert at any per se, but relatively good at all of them. Like a good dual sport bike.

Bought this '93 last October.

Body and interior are excellent (minus the paint), motor has 206,XXX miles, but runs strong and smooth.
Will likely replace it with a reman. when it croaks.

Day I got it:


How it sits today:



Motor/Exhaust:
Want to get extra juice out of the 351W while keeping it reliable; mild bolt on stuff.

-Sixlitre tuneup (done)

-Bassani Y pipe and Magnaflow muffler, 3" all the way through (done)

-Edelbrock 3881 Truck Performer Intake (next up)

-BBK 56mm TTB (next up)

-Cam: Edelbrock Performer or Comp Cam 35-512-8 or ? (will wait til engine rebuild or replacement)

-Shorty headers: haven't decided (will wait til engine rebuild or replacement)

-Heads: haven't decided (will wait til engine rebuild or replacement)

Suspension
Still reading up and learning; haven't decided on a shop yet.
For my goals/purposes, I think I would be happy with 12"-15" of travel.

Front:
-Cut n' turned beams

-4" coils

-Extended Radius Arms with Pivot Brackets

-Drop Pitman Arm

-Fox 2.0 or Bilstein 5100 shocks

Rear:
-Deaver J40 or Q80 springs

-Fox 2.0 or Bilstein 5100 shocks


Gears
-4.56 ring/pinion (done)

-Detroit TruTrac in the rear (done)

-Open in the font


Wheels/Tires
-Pro Comp 15x8 (done)

-General Grabber AT2 (done)


Miscellaneous

-Cage: Installing a 4 point cage; I had one custom made by All4FunOffroad like the one found on the Operation Fearless Bronco

-Paint: Friend of mine owns a body shop and is going to let me paint it for the cost of the supplies (I'll be doing most of the work with his guidance); will start on that in a few weeks; thought about installing fiberglass, but since the body is in great shape, I really don't want to cut it up.

-Seats: PRP, Mastercraft or equivalent at some point


That's all I can think of for now; will update accordingly.


I welcome any and all advice you guys have for me!
 

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Addicted to Junk
85 Bronco, 309ci I6 w/4bbl, np435, 4" lift, 37" Irok NDs, 4.56 w/ Detroit Locker and tru trac
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12,013 Posts
Solo is about the best. But there's a few more making these LT kits. Threat is the only one that comes to mind right now.

Start fresh. The whole point of cut and turned beams is to do away with drop brackets.

4000 will get your suspension and not much else when doing this level of suspension work.
 

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Solo is about the best. But there's a few more making these LT kits. Threat is the only one that comes to mind right now.

Start fresh. The whole point of cut and turned beams is to do away with drop brackets.

4000 will get your suspension and not much else when doing this level of suspension work.
This is good advice.

But, keep in mind.... your current lift may have required the cutting out of the factory TTB pivot brackets. If so, you'll need to ditch the drop brackets and then figure out how to re-install factory for cut and turned beams to bolt into.

I swapped a 2.5" lift for a buddies 6" lift and it was a huge bummer when we realized I had to carefully remove my factory pivots to reinstall in his truck. Kind of a pain but totally doable.

You should take a peek under your truck so you can plan accordingly.
 

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Discussion Starter #4
This is good advice.



But, keep in mind.... your current lift may have required the cutting out of the factory TTB pivot brackets. If so, you'll need to ditch the drop brackets and then figure out how to re-install factory for cut and turned beams to bolt into.



I swapped a 2.5" lift for a buddies 6" lift and it was a huge bummer when we realized I had to carefully remove my factory pivots to reinstall in his truck. Kind of a pain but totally doable.



You should take a peek under your truck so you can plan accordingly.

Can you tell from these pics?

 

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Addicted to Junk
85 Bronco, 309ci I6 w/4bbl, np435, 4" lift, 37" Irok NDs, 4.56 w/ Detroit Locker and tru trac
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12,013 Posts
Yep, you will have to ditch those brackets and get new stock ones. (Pic 7, held on with the shiney bolts)
 

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Ford Hoarder
78 & 92
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Threat and Solo both make replacement center TTB pivots. Also Giant and maybe autofab do as well. Southwest performance may too but I am not sure you would have to email and/or call.
I would also decide now if you were going to ever go to uni-balls in the ttb pivots as that may change the mount accordingly.
https://www.solomotorsports.com/shop/parts/ford-parts/suspension/dana-44-ttb-pivot-brackets/

What is you current lift not doing or doing that you want to change it??

Also I would check out Threat, Desolate, and Giant for an entry level kit like that one from Solo. The solo stuff is very nice and I am sure you would like it but always good to look at your options too, I think
 

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Utah Broncospeed
1996 Bronco XL, 5.0 (N), E40D, Autofab long travel susp, Race-Runners 2.5" res. (6), 35x12.50R15
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185 Posts
Give Autofab a shot too!

Thanks for the replies everyone.
Gonna do more reading and make some calls.
Please do call John Ehmke at Autofab. He does it 'old school', and is the system that I selected for my build 8 years ago (Utah Broncospeed: http://www.fullsizebronco.com/forum/52-broncospeed/146007-utah-broncospeed.html )

Check: www.autofab.com

Note: John now seems to be selling his components 'a la carte' and not as a complete system (C&T beams, radius arms, brackets, coil spring buckets, shock hoops, etc.) so you have to ask...

I purchased his long-travel 2.5 shock system (supposedly 16" F&R) utilizing dual S-A-W (now "aFe Control") 2.5" reservoir shock at each corner at the front, and a single 2.5" res. shock on the back at each wheel...and its been a great system. Yes, it was grossly over-shocked, but I finally rectified that last summer by having all 6 shocks rebuilt and tuned (90% reduction in stiffness in the front, and about 70% reduction in stiffness in the read), and its a totally different vehicle (that work performed here in Utah by Matt Bell at DesertSpeedShockTuning.com). So whatever you purchase, get the shocks/coilovers/bypasses tuned from day 1. It is money well spent.

I'm sure these other manufacturers/fabricators have much more elegant and modern single-shock solutions (Solo, Camberg, etc.) but there are a lot of alternatives. Do your research and yes, make those calls!

Good luck.
 

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Also I would check out Threat, Desolate, and Giant for an entry level kit like that one from Solo.
Never heard of Desolate. Their stuff really looks good.


OP, contact everyone you plan on using. Granted my experience with one of the vendors mentioned here was years ago and things may have changed but I had things all planned out to go one route. Tried to get info before ordering and never heard back from that vendor after many emails and calls. Had to change direction and my truck was one year completed and on the road, out of nowhere I get an email from that vendor. Yeah.

Nice stuff is great but if you can't get the parts its just pictures on a web page.


Good luck,
Mike
 

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Ford Hoarder
78 & 92
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Agree with the Above.
Desolate Stuff is very nice, I have a set of rear shackle hangers and Axle side shock mounts from them. Everything is top notch quality wise and the guys at the shop are very easy to get a hold of and work with. I will be repeat customer. I tend to be that person that gets screwed by vendors so that means something coming from me.

My experiences with Solo, Giant, and Threat have all been good too though. Threat is sometimes hard to get ahold of but even with that, they have always gotten me my stuff in a reasonable time and the parts have all been of good quality. They have worked with me making some tweaks to things as to fit my '78 better too.

In general I find that a lot of the good parts for these trucks are made by relatively small shops, so patience is key and you will be rewarded. Just try to keep in mind that the person your talking to may very well be the same one burning your parts together too
 

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Discussion Starter #11
Cage arrived.
Plan on getting it welded/mocked up later this week.
Then off to powder coat.

In addition, my roof rack sits too high for my liking; while at my fabricator's shop, I'm gonna see if he can shorten the mounting "feet" to get it to sit closer to the top.
 

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Discussion Starter #12
Pics from Friday of the cage getting put together.


No pic of the crossbar.
Getting powder coated tomorrow.


Today was beautiful. Shot a USPSA steel match this morning, then went up for a mountain drive with the wife.
 

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Discussion Starter #15
Like the cage any more info would help
Any photos of the mounting at forward tubes
Thanks!

I had the cage custom made by All4FunOffroad like the one found on the Operation Fearless Bronco.

I'll try to get some pics of the mounts.

3/8" steel plate < body > 3/8" steel plate
Grade 8 hardware

At some point, I'd like to tie it to the frame for better piece of mind, but it'll have to do for now.
 
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