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New Updates 5/12/2005<--(w/Big Mike Bumper)

3349 Views 15 Replies 7 Participants Last post by  JoeBob1901
Well I have some pics of some new updates. I have been pretty busy the past two weeks; I quit my job at the tractor trailer shop and got a new job as a tech at VW....

Here's some updates on my Bronc.....

I wanted to strethen my gigantic trac bar mount, so I gusset'd the front and back of it with some 3/8' steel...








the new tranny/radius Arm mount was bowing becuase of the weight of the tranny on it. So I laid some 1.5" angle iron on it and welded it straight across in the back, and laid another piece in the front to keep it straight, and it worked......







I finally replaced the inner carrier seals in the D44, so it doesnt leak any more, I got the new ujoints and mounted my front shaft in place. BUT I think the shaft is too short now? Here are some shots from the rear yoke on the T-case. The splines are coming out about 1" (theres about 4.5" of spline total). Will this be ok, or should I have the shaft lengthened? Also, I have some shots of how I routed my brake lines, so if anyone is doing the same swap, heres some ideas....







I realised that my trac bar was actually hitting the frame, where the TTb used to mount, and I thought It would be ok,.....I was wrong. Its hitting it pretty bad, So Im going to have to cut the frame, just havent done it yet,



I finally got the Bilstein 5150's mounted up, and the truck rides friggen awesome now. I got the heavy vavling (255/70), because I chose to run 2 shocks up front and not four. I will probably get the 5100's in the back when I can get some money...Also, anyone with the Cage Arms have tire rubbing issues? Its probly becuase of my 4 3/4" backspacing, but my tires rub the shocks mounts on my Cage Arms....Anyone else have this problem?




I knew my rear shackles werent doing too well, and I now have some "cancer" on the pass. rear shackle. Its rotting right thru, so I will be doing new shackles very soon.....



And Finally, I got my Big Mike Bumper. I painted it Rustoleom "Hammered" Balck, about 3 coats, and then cleared it once or twice. Mike makes an awesome bumper, and I would suggest buying one from him for your bronco. This thing is Sweet, well thoughtout, and excellent craftsmanship! He made mine with a triangle style swingout tire carrier, with 8 on 6.5 lugs to fit my 37" (when I can afford to get a spare, lol) The gas shock, the reciever and the D mounts look awesome! This thing is one stout bumper, and it fit excellent!...








I remounted the stock spair carrier mount back on the truck for a few reasons. One, I hate the look of the bolts just bolted to the body, and two; Im going to use the top mount for my new CB ant. I repainted them to match the bumper, and they look pretty good next to each other. The rear one I had to cut down to fit it between the body and the new bumper. It worked out good, becuase my tailgate drops down so much, so I need to remove the gas shock every time I lower the tailgate or it hits (the tailgate straps must be worn out or maybe the gas shock is mounted to high) So the bottom mount acts as a "stop" so the bumper doesnt slam the body.


..And so the saga continues...... :cool:
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1 - 16 of 16 Posts
looking good

replace those rear hanger before you drive it anywhere!!!!!!!

this was a project i had bought, but sold recently after i put all new leaf hangers and sahackles on it.

i bought the truck this way



it actually came off the frame in 2 peices


thge other side was not far behind it






i figured you might have problems on the trans mount bowing, glad it was an easy fix

might consider moving the rear hella's, those are not cheap lights to replac when the break

other wise looks great, love that bronco
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oh those old tire carrier mounts come right off the quater panel, it should be clean under there, might have rub out the paint a little to be perfect.
i just put the bolts back in place, never would really know. a body shop could weld and paint them up fairly cheap too
Thanks for the tips.

On the topic of the rear lights, Im going to move them forward, closer to the gas tank, so the dont get whacked offroad...

The old mounts have been off before, infact I had the old tire carrier off for about a year before, I was going to bondo/weld the holes shut and do some body work, but Im going to replace the entire rear fenders and tailgate in the future, so what i did works for now...

I want to do the rear hangers, but I want to do a new tank and pump too, so I need to save some money. Im not going to drop the tank twice, Ill just wait, and be easy on those rear hangers, :shrug (probly not a good idea leaving them like that)
Looks good, definitely ditch those shackles.

I would move the lights to the old spare tire carrier mount. They wont last long down there.
Haustkraft said:
Thanks for the tips.

On the topic of the rear lights, Im going to move them forward, closer to the gas tank, so the dont get whacked offroad...

The old mounts have been off before, infact I had the old tire carrier off for about a year before, I was going to bondo/weld the holes shut and do some body work, but Im going to replace the entire rear fenders and tailgate in the future, so what i did works for now...

I want to do the rear hangers, but I want to do a new tank and pump too, so I need to save some money. Im not going to drop the tank twice, Ill just wait, and be easy on those rear hangers, :shrug (probly not a good idea leaving them like that)

i never dropped my tank, it takes some creative thinking, but you can actually get to the back side of those bolts, providing you have a pretty extensive selection of sockets and wrenches
blueoval78 said:
i never dropped my tank, it takes some creative thinking, but you can actually get to the back side of those bolts, providing you have a pretty extensive selection of sockets and wrenches

Really? I will have to look at it more clearly tommorrow, maybe I will be doing them sooner than I think!
Lookin good. That big mike bumper is one strong piece of steel. I got a good look at 2 of em this weeked
Looks good.

I would think you will be fine with 1" showing/3.5" still left in there. If you want I can get you a measure of what my shaft length was with my 4.5" front lift (the shaft is off sitting in the garage, and I notated the length so that I can compare after SAS). But IIRC, my shaft had about 1/4 showing anyway. I know you should get some real good down travel, so you proabably need to just go out and poser it and get under there and see (or have someone do this while you flex it).

Why more gusset on the top Tbar, looked awefully strong to begin with?

I now understand your ordeal with the stripped out radius arm C bolts...I had another FSBer come over for another set of hands to test fit mine. Don't think I can get them on by myself, and if you start them at all wrong, you'll mess up the threads.

did your truck settle any more? What did you end up with for clearance between the track bar and top o diff at closest point, with truck just sitting?
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thejuice said:
Looks good.

I would think you will be fine with 1" showing/3.5" still left in there. If you want I can get you a measure of what my shaft length was with my 4.5" front lift (the shaft is off sitting in the garage, and I notated the length so that I can compare after SAS). But IIRC, my shaft had about 1/4 showing anyway. I know you should get some real good down travel, so you proabably need to just go out and poser it and get under there and see (or have someone do this while you flex it).

Why more gusset on the top Tbar, looked awefully strong to begin with?

I now understand your ordeal with the stripped out radius arm C bolts...I had another FSBer come over for another set of hands to test fit mine. Don't think I can get them on by myself, and if you start them at all wrong, you'll mess up the threads.

did your truck settle any more? What did you end up with for clearance between the track bar and top o diff at closest point, with truck just sitting?

I will get some measurements tommorrow. Im going to use the lift at work tommorrow and flex the shit outta my truck I think, or maybe wait until firday. Ill get some shots from everyt angle

I gusset the mount just incase. I didnt know if the mount wieghted to much to just have it welded like it was, I just wanted more strenght from forward and rearward movement. I just wanted overkill i guess, lol....

I didnt cut the frame yet, I need to either find some one with a plasma, or just bit the bullet and used the cut off wheel....
Haustkraft said:
Really? I will have to look at it more clearly tommorrow, maybe I will be doing them sooner than I think!

its not by anymeans easy, but removing the bumper and the trailer erciver if you have one is a must. i did not have the abilty at the time to drop the tank for several reasons. but it takes some creative thinking, and some long thin fingers. doing things like wrapping your finger with duct tape with sticky side out helps get the washers, and nuts started on the back side. a good selcetcion of elbows, and extensions helps too
Plasma, spasma.

Love to have one, but I can tell you now the crossmember is coming off by cut off wheel and/or hack saw for me.

No pain no gain.
that taurus is the hotness! lol rob would have been done ages ago if he didn't take so many pics.. :brownbag
thejuice said:
Plasma, spasma.

Love to have one, but I can tell you now the crossmember is coming off by cut off wheel and/or hack saw for me.

No pain no gain.
sawzaaaaaaaalll, cheap alternative :thumbup

Bronco looks really sharp, you should be pleased :thumbup
JoeBob1901 said:
sawzaaaaaaaalll, cheap alternative :thumbup

Bronco looks really sharp, you should be pleased :thumbup
yea, forgot about my sawzall, so one of those will hack it up. :thumbup
thejuice said:
yea, forgot about my sawzall, so one of those will hack it up. :thumbup
That'll buzz through it like nobodys business :rockon
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