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Discussion Starter · #1 · (Edited)
300+ pictures and a write up on every process of the build. Lots of prep led to a 5 day drivable install.

If those reading this use the same parts, mostly from online resources, you can make your swap bolt on using my techniques, measurements, and a few cuts on your stock radius arm mounts. Total build cost is in the 3000 dollar range. As was said many times before there are great gains from being able to weld but not everyone has the means to add that expense to their build. All parts below can be ordered welded and ready for install, the one caveat to this is the axle welds may need attention and if that is the case you may as well weld the tubes to the differential for added strength.

INDEX
PAGE 2/3 - Radius Arm research and purchase, Coil buckets and axle mounts, first parts list
PAGE 4 - Shock mount talk and shock decisions
PAGE 5 - My track bar mount, radius arm beef pictures
PAGE 6 - Parts Gathering, Axle cleaning, axle tear-down
PAGE 7 - Electrolysis begins, parts gathering
PAGE 8 - More parts gathered, electrolysis more parts
PAGE 9 - Electrolysis an entire solid axle, electrolysis knuckles, brake mounts, entire axle, painted parts
PAGE 10 - Welded axle tubes and steering, reamed knuckles, painted axle gloss
PAGE 11 - Painted axle flat, Yukon spool, ball joint install and inner axle seal install
PAGE 12 - Axle shaft and U-joint assembly, coil bucket height differences, ECTED e-locker ordered, spool for sale
PAGE 13 - Brakes talk
PAGE 14 - Installed my own gears, drilled for electronic locker wires, spindle bearings, outer slinger, spindle seal install, mostly assembled, ready for install.
PAGE 15 - TTB removal, track bar mount installed, rivets cut and TTB buckets removed.
PAGE 16 - Buckets installed, shock mounts installed, axle mocked up, heavily modified stock radius arm brackets installed. Bilstein 14.5" Travel Shocks ordered.
PAGE 17 - Stock track bar cut down and re-welded for temp use, 1 ton drag link all ready to go
PAGE 18 - Stock modified track bar pics, complete solid axle install including brakes, hubs, warn lockouts, brake lines, brake calipers, drive shaft connected, more...
PAGE 19 - 15" travel shock install, front and rear custom e-locker switches
PAGE 20 - rear lift blocks (suck) installed, e-locker switches installed, 4 month hiatus (Loadmaster Air Force Deployment), BULLETPROOF track bar ordered
PAGE 21 - BULLETPROOF track bar talk, Deal of the decade welder purchased
PAGE 22 - Welder Pics, Bulletproof track bar installed, Rear Hefty Shackle flip install began...
PAGE 23 - Rear Hefty shackle flip install VIDEO, SAS on the street VIDEO, and putting the final tweaks on entire suspension
PAGE 24 - Stock Radius arm frame side mount revisited with pics

SPECIAL CONSIDERATIONS ARE IN BOLD BELOW
If you used my thread for your build please reference it in your build. I like knowing I could help out. ;)

FRONT DRIVETRAIN/SUSPENSION--------------------------------------------------------------------------------------------------------------

Freebees
New Yukon Dana 44 reverse 4.56 gears (new from previous owner)
SS Crown brake lines (new from previous owner)
Warn hubs (installed on the TTB and reused)
Brake rotor, hubs, bearings (installed on the TTB and reused, reuse/reman the knuckles, spindles, and brake caliper & brackets from the 78 axle)
Radius arm mounts modified stockers
stock pitman arm
Reamer/251 Miller welder - off road club provided
3/16" Dana 44 diff cover

Dallas Ft. Worth Craigslist
1978 Ford Bronco Axle brake to brake with extra parts- 275+75 bucks in gas to pick the pig up

Broncobob.com
HD Extended arms with caps 544 shipped

James Duff
HD Coil buckets and HD bottom cups 200 + 31 shipping *66-77 buckets

extremecustomparts.com
(1) 1 1/2" O.D. x 1/4" wall D.O.M. tubing Cut down and welded to 23-1/2" bung to bung, Drag Link
(1) 1 1/2" O.D. x 1/4" wall D.O.M. tubing Cut down and welded to 46 1/2" bung to bung, Tie Rod
(2) 7/8-18 LH threaded inserts
(2) 7/8-18 RH threaded inserts
(2) 7/8-18 LH Jam nuts
(2) 7/8-18 RH Jam nuts
(1) ES2026R DLE
(1) ES2027L DLE
(1) ES2233L TRE
(1) ES2234R TRE
1ton complete steering system not welded 216 shipped (this can be ordered welded with my measurements)

broncograveyard.com Excellent Value and customer service has been good!
Dana 44 Overhaul kit, Timken Bearings 85.00 1 85.00
Super Flex Coil Springs, 5½" 140.00 1 140.00 *66-77 springs
Radius Arm Bushings, Black Rubber 45.00 1 45.00
F250 Upper Shock Bracket 23.00 2 46.00
C-Bushings, 2 Degree Black 29.001 29.00
Total Shipped with 10% Discount - 385.35
Order 2/3
22028 D44 Outer Axle Shaft, Stub Axle 1 $48.00 $54.00 shipped (spindle bearing failure ate .020 off the original shaft)
22056 D44 Axle Shaft U-Joint, Spicer 2 $25.00 $55.00 shipped
D44 Spindle Bearing Repair Kit 10.00 2 28.00 shipped
Order 4
Inner axle seals 20 shipped
spanner for ball joints 20 shipped
Order 5
Outer axle slinger behind outer u joint 10 shipped
Brake banjo bolts for 78-79 calipers 10 shipped
Order 6
Genuine BULLETPROOF Track Bar for 78-79 Bronco 32.5" 190 shipped

NAPA
260-1342 NCP Ball joint 2 70.98
260-1343 NCP Upper Ball Joint 2 77.58
PBR37 Front Bearings 2 21.38
PBR35 Front Bearings 2 17.38
24917 Wheel Seal 2 11.78

TOP GUN Customz TERRIBLE CUSTOMER SERVICE (canceled all other orders I had with them)
Track bar mount SuperDuty F250-F350 99-04 Tuff Country 20905 96.00 shipped

rightgear.com
Auburn ECTED (made in the USA) electronic locking differential 651 shipped

Advance Auto Parts
Saginaw Pump 50.00 + 10 dollar pulley (not sure if it was worth it, performance is the same)

Oreillys Auto Parts
Brake Calipers 2.88 Cylinder/Organic Brake Pads 72.00
Gear Oil 15 bucks, brake fluid 4 bucks

Local Fastenal
1/2 bolts, nuts, washers 60 bucks
3/4 bolt, nut, washers, lock washer for trackbar 8.75
Wheel bearing grease rated for disk brakes 5.00
(2) 2.5" long half inch bolts 1.80

Local 4x4 Store
34/19" 15 inch Procomp 334000 Shocks 97 /Pair

REAR DRIVETRAIN/SUSPENSION-----------------------------------------------------------------------------------------------------------------

broncograveyard.com
Rear 4" Lift Springs Superflex 549 (shipping extra)

Hefty Fab Works
4.5" Shackle Flip 170 shipped
 

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Discussion Starter · #3 ·
when do you actually come home to actually start progress on it?
Dont want to give way exact dates but in a few weeks. Lets say end of February...

Here is the beginning of my project. I am in Iraq gathering parts for this SAS online. Only in the 21st century can you wheel from your laptop... after looking long and hard I found this...











... and bought it for 275.
To be continued...
 

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keep your ass safe till the very end and good luck on your build. My SAS started in the same way . . in the same theater!! And still a year later after getting home I am still gathering parts. . .DOH!!
 

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Discussion Starter · #5 ·
Thanks goose!

UPDATE! I did 3 hours searching for best price on the best steering! Lots of work. But to help you all out you will not find a better deal than extremecustomfab on ebay. they ahve 100 percent feedback on their parts and they will let you make offers on their product. I bought their 200 dollar kit and made them an offer and they took it! Cant wait for the kit but here is a pic of the setup. I have a freind back home that has a reamer so I am set there.
(1) 35" LENGTH OF 1 1/2" O.D. x 1/4" WALL D.O.M. TUBING
(1) 47" LENGTH OF 1 1/2" O.D. x 1/4" WALL D.O.M. TUBING
(2) 7/8-18 LEFT HAND WELD IN THREADED INSERTS
(2) 7/8-18 RIGHT HAND WELD IN THREADED INSERTS
(2) 7/8-18 LEFT HAND JAM NUTS
(2) 7/8-18 RIGHT HAND JAM NUTS
(1) ES2026R DRAG LINK END
(1) ES2027L DRAG LINK END
(1) ES2233L TIE ROD END
(1) ES2234R TIE ROD END

 

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I'm subscribed :thumbup and thanks for that tip btw!
 

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:stupid

Looks like a great start. I couldnt get rid of the D44 I had in my garage for $75 and here you payed $275....right place/right time I guess. I'll be following this as other project have put my SAS on hold.
 

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Discussion Starter · #9 ·
I'm subscribed :thumbup and thanks for that tip btw!
Your welcome, looking for radius arms and this is the difficult part since they are ALL so expensive, wanna go extended not stock.

How much did you offer them?
I dont feel that is fair to the company but I did my research and found that you can find the going rate on their products by searching their feedbacks, it will list the price that people offered and they took. Hint hint.

:stupid

Looks like a great start. I couldnt get rid of the D44 I had in my garage for $75 and here you payed $275....right place/right time I guess. I'll be following this as other project have put my SAS on hold.
Thanks, wish I had found your axle first LOL, the thing is you have to be close to someone for a good price, shipping kills the deal for most cause its at least 200 freight, then you also have to go pick it up, not hard just not as nice as having it on your doorstep.

Standby for the moment, I am looking for radius arms and have found two places that I have narrowed it down to for one price... two quality...

First one is broncobob or All 4 Fun offroad. Sent an email and never got a reply :twak, his arms are 389 at broncobob.com anyone have any experience with this company?

Second one is James Duff, pure awesome quality at a price. Engineered for you but man 699 + 85 end caps + bushings + springs = over a thousand! :barf May be my last resort if nothing else comes to fruition.
 

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broncobob.comStrut arms to rear $389.99 with exchange for arms with caster built in for 3 1/2 inch lift. $389.99 for arms with caster built in for 5" lifts and yes they do fit Ford pickups and 78-79 Broncos adapter bracket for Ford pickups and 78-79 Broncos $229.00 bolt in setup
So do you need to buy the adapter bracket as well to fit the fullsize's.
 

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Discussion Starter · #11 ·
So do you need to buy the adapter bracket as well to fit the fullsize's.
It seems to me only if you want to make it bolt in and have no fabbing or other parts to work with then YES; otherwise, I have custom brackets already so I dont need these to make it bolt in for me.
 

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Discussion Starter · #13 ·
Do you have the stock radius arms to exchange at broncobob? do they list the price without exchange?

Some other options:

http://www.wildhorses4x4.com/category/s

http://www.tomsbroncoparts.com/product.php?category=107&id=1098
i have wondered that about the core charge. I dont have cores so mine are going to cost a bit more. Broncobob has not got back to me so they are about to lose out on a sale as I had said somewhere on here before... For completeness there is just no beating james duff.
 

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I think in the long run it is totally the smart move to make.

Until Jim comes out with his new radius arms v3.0!!!

Of course they will most likely be more expensive still..........
 

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Discussion Starter · #16 ·
I was able to score like new black no rust 77 radius arms for 26 bucks. I may use these as cores but the duff stuff is still where my heart is at. Just need to get the rest of wallet to follow.


Here is the thing, I can afford them but I have been doing so well with my money lately that i have become super frugal. I blame Dave Ramsey. Well anyway I am out of debt and I make a decent income as a Sergeant in the Air Force, not counting perks, bonuses, deployment money. The value now has to be there for me and I know I will end up spending more down the road fixing what I should have done now... just buying the Duff stuff.

Still looking around.
 

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I outta do that soon when the hours pick back up from 5 a week...
 

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....Here is the thing, I can afford them but I have been doing so well with my money lately that i have become super frugal. I blame Dave Ramsey.....
I've been listening to him a lot lately too. Good for you getting out of debt! It sure is a liberating feeling knowing you don't owe anyone anything.

Good luck on your SAS. Looks like you have a good start on it so far.
 

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Looks good so far, that steering linkage is long enough for a full width dana? just curious because of 66-77 bronco jeep title i know they arent full width?
 
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