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Chuzie's monster transformation - chuzie - 09-22-2010
Day 8 (22 Sep 10)
Objectives for today:
1. Finish front end
2. Finish installing rear coils
3. Install rear shock truss
4. Weld all components
5. Complete 4-link suspension installation
6. Install wiring harness
Today I buttoned up the loose ends on the front end to include the brake lines, power steering box, and linkages. Objective 1 complete.
![[Image: P1020162-1.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020162-1.jpg)
I spent the day prior rechecking all the measurements of the axles one last time before we welded up all the bracketry. I found the front had one side longer than the other by 1/8" so I had to lengthen the opposing radius arm about a turn and a half. Once I was sure the front end was square I moved to the rear. Since the front was off, I had to readjust the rear to make sure it was square to the front. This adjustment also threw off the alignment of the upper coil towers but I had to remove them anyway to adjust the ride height issue mentioned in the previous workdays. We wont break this out as a separate work day but will add the hours to the total.
The project has been on hold due to the excessive height in the rear. Chuck and I determined the only solution to make this work was to raise the upper towers as far as the floor would allow and then to cut about 1/4" off the crown of the towers. This gave us about 1.5" to lower the rear. Recent measurements prior to this modification show the rear to be 2" high so this would give us the needed 1/2" high ride height as recommended.
Once we cut the towers we realized that having the them flush with the floor prevented us from having access to secure the backside of the nuts for the coil retainers. The initial solution was to weld the nuts to the top side of the tower but the nuts were to large and protruded above the crest of the tower and we could not grind them down enough without getting into the threads. The solution was to weld a bolt from the inside pointing out and we would just thread a nut on the outside. The idea worked and the towers are now in place and functioning well. Objective 2 complete.
![[Image: P1020194.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020194.jpg)
![[Image: P1020196.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020196.jpg)
Next I installed the shock truss 11.25" forward of the coil towers. I had to trim just a hair from the body to make room for the bolt head but otherwise it went in without an issue. This was, by far, the easiest task of the project! Objective 3 complete.
![[Image: P1020197.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020197.jpg)
With the towers in place and all measurements indicating we are within limits, Chuck went ahead with the full welding of all the hardware on the frame and the axle. He was a real champ and knocked it all out in about 3 hours during a nonstop marathon session in the heat while fighting the dreaded blue power coating which kept making the welding difficult even though we ground down 1/2" on all surfaces. Chuck is the man and his dedication and effort is much appreciated. Objective 4 complete.
![[Image: P1020199.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020199.jpg)
![[Image: P1020204.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020204.jpg)
The kit included two inserts to add strength to the rear truss in the center over the differential. This is a fix Duff's included as they have been having issues that cracks in that area. I think mine was the last truss to go out that did not already have this fix incorporated. I ground them down to fit and Chuck welded them in place. It would have been nice to know about this before we tacked the truss in place but there was no reference to it in the instructions.
![[Image: P1020200.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020200.jpg)
Once the welding was done we reinstalled the rear axle, installed the shocks, coils, and tires. The rear is still about 3/4" to 1" high but I want to let the springs settle overnight before I pass final judgment. It looks great and we are really excited. Objective 5 complete. (we think)
![[Image: P1020205.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020205.jpg)
![[Image: P1020207.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020207.jpg)
While Chuck was welding I started with the new wiring harness. It will be mounted on the drivers side instead of the passenger side and I plan to copy as much of the stock routing as I can while making improvements as I see fit along the way. There are lots of circuits too which gives me the flexibility I want. I added three wires to the rear harness just for future expansion. The plan tomorrow is to case the rear harness in 5/8" rubber hose to protect it in the frame and then fish it through the frame, along with the fuel lines. Objective 6 incomplete.
![[Image: P1020201.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/bronco%204link/P1020201.jpg)
By the end of the night all the welding was complete and the wiring harness is on its way to being installed. The project is definitely in the final stages.
Day 8 complete.
Objective 6 incomplete
Man Hours worked: 16
Total Project Man Hours: 76
Chuzie's monster transformation - blazinchuck - 10-07-2010
how bout an update jerky...lol
Im ready to start on some exhaust stuff now!!!
Chuzie's monster transformation - chuzie - 10-09-2010
Things have been slow lately. I am frequently stopping work for my job and the wiring has really been slow.
The wiring harness is installed and 95% functional. I still need to get hold of some stock terminals to adapt the dash wiring to the stock plugs in order to clean it up a bit. I tried to use splices to the old plugs but it just made a huge mess of the dash and looks like crap so I need to take the time to make it right.
Also, it needs to be loomed, the NSS and reverse lights need to be hooked up, and I have to work an issue with the turn signals. They do not operate when the switch is actuated but they do work with the hazard switch so it is just a matter of shooting some wires.
I need to determine if the rear driveshaft is going to work since we moved the axle back 2" but I really need to be able to fully extend and compress the suspension for that so we will have to wait until it is mobile. Maybe next week.
The exhaust is also another hurdle. A set of 90 degree pipes are on order so we can try to route the exhaust over the frame. They should be here next week.
Other than that, everything is going well and I suspect the rig will be complete in the next week or 2.
Chuzie's monster transformation - chuzie - 10-27-2010
I finally got back at it yesterday after being out of town again for a couple weeks.
The wiring is done and everything is functional. Unfortunately i am going to have to live with the unsightly wires i have spliced into the dash area until I get back URE. The plan is to install stock terminal ends but we are running out of time so for now I will have to settle with function over form.
We determined the driveshaft I have have installed will work even considering we moved the axle aft 2". Normal ride height leaves about 2" of spline on the shaft so in theory, the shaft would have to rotate down 8" to come separated. I do not plan to do any jumps so this is a non issue for now.
Chuck and I bled the brakes and backed the rig out of the harage for the first time in months. It was great even though the exhaust was not yet installed. We did some testing to make sure everything was working ok.
This suspension is very soft and the complete opposite to the ultra stiff suspension I have been running for 8 years. My initial concern when going down the road was the amount of lean I experienced at speed when simulating a sudden wheel movement. We immediately began thinking of how to create a sway bar but that is still on the drawing board. We also clocked all the links to try an remove any additional source of movement.
We flexed it out in a ditch and all went better than expected. We will have to trip about an inch of the front fender that was getting into the front of the tires when maxed out but other than that we are good to go in terms of the suspension.
Chuck has done a magnificent job on fabricating the exhaust considering the challenge the new setup brings. We completed the left exhaust and will be working on the right side tomorrow. Our goal is to have that completed and continue testing in the next few days prior to URE.
More pics are on the way just have not had a chance.
Man Hours Worked: LOST TRACK. JUST DOUBLE THE LAST KNOWN FIGURE!!!
Chuzie's monster transformation - chuzie - 11-20-2010
I promise I am going to finish this build thread soon. Things have been really busy and I want to get the rig up on an RTI and provide proper pictures and results. More to come....
Chuzie's monster transformation - chuzie - 01-14-2011
So I came up with a list of a FEW things I need/ want to do to the Bronco. Figured I would share.
1.6 roller rockers
4-link wrenches
Atlas transfer case
Bump stops
Cold air setup
Dynamat
E-303 or Steeda #19 cam (not sure if either is appropriate for the Bronco)
Engine bay fire extinguisher
Engine fire blanket
Engine tuning possibilities???
Fix rust on rear quarter panel seams
Fluid chip detectors
Front side marker lights
GT-40P Explorer or GT-40X heads
H or X pipe
Heater box deflectors
Kill switch
Locate original glove box door
Lucas Oil
On-board welder
Passenger handle
Repair rocker panel hole
Setup windshield washer system
Steering wheel
Trailer brakes unit
Underdrive pulleys
*** 70mm MAF *** COMPLETE ***
*** Adjust TPS *** COMPLETE ***
*** Adjust tranny modulator *** NOT NEEDED ***
*** Alignment *** COMPLETE ***
*** Ammeter gauge *** NOT NEEDED ***
*** Anti theft implementation *** COMPLETE ***
*** Battery holder *** COMPLETE ***
*** Bellhousing bolt *** COMPLETE ***
*** Bumper lights *** COMPLETE ***
*** Ceramic headers *** COMPLETE ***
*** Ceramic tire balancing *** COMPLETE ***
*** CG calculations *** COMPLETE ***
*** Dual battery setup *** COMPLETE ***
*** E-track *** COMPLETE ***
*** EEC test switch *** COMPLETE ***
*** Electrical oil press gauge *** COMPLETE ***
*** Electrical water temp gauge *** COMPLETE ***
*** Explorer injectors *** COMPLETE ***
*** Explorer or Cobra GT-40 U+L intake*** COMPLETE ***
*** Fix column cover *** COMPLETE ***
*** Fix rear view mirror lights *** COMPLETE ***
*** Fix speedometer *** COMPLETE ***
*** Fix tachometer *** COMPLETE ***
*** Flush coolant *** COMPLETE ***
*** Front and Rear Diff guards *** COMPLETE ***
*** Front driveshaft CV repair *** COMPLETE ***
*** Front roll cage *** COMPLETE ***
*** Gorilla war flares *** COMPLETE ***
*** Half-shaft TB mod *** COMPLETE ***
*** Heater control line *** COMPLETE ***
*** Hood bumpers *** COMPLETE ***
*** Hood shocks *** COMPLETE ***
*** Horn *** COMPLETE ***
*** Inclinometer + warning system *** COMPLETE ***
*** 65mm TB *** COMPLETE ***
*** Idle boost switch *** COMPLETE ***
*** Install plug wire holders *** COMPLETE ***
*** Install TB cooling lines *** NOT NEEDED ***
*** Install windshield chrome trim *** COMPLETE ***
*** Kids Car seat LATCH system in rear *** NOT NEEDED ***
*** Lever Locks *** COMPLETE ***
*** Magnetic fluid plugs *** COMPLETE ***
*** Mechanical oil press gauge *** NOT NEEDED ***
*** Mod scissors jack for axle *** NOT NEEDED ***
*** Modify bumper to reflect old bumper *** Never gonna happen ***
*** Move brake line off header *** COMPLETE ***
*** Nerf bar grip tape *** COMPLETE ***
*** New oil dip stick *** COMPLETE ***
*** New tires *** COMPLETE ***
*** Obtain spare rear axle shafts *** COMPLETE ***
*** Onboard air *** COMPLETE ***
*** Paint door inserts ***COMPLETE***
*** PS cooler *** COMPLETE ***
*** Radiator fan shroud *** COMPLETE ***
*** Rear axle seal *** COMPLETE ***
*** Rear brake cylinders *** COMPLETE *** (installed rear discs instead)
*** Rear diff fill plug *** COMPLETE ***
*** Rear Pinion guards *** COMPLETE ***
*** Rear seat *** COMPLETE ***
*** Redneck ram *** COMPLETE ***
*** Reduction gear starter *** COMPLETE ***
*** Relocate coil *** COMPLETE ***
*** Relocate O2 sensors *** COMPLETE ***
*** Repair bikini top hole *** COMPLETE ***
*** Repair + paint beadlocks *** COMPLETE ***
*** Repair right windshield gutter *** COMPLETE ***
*** Repair shift indicator *** COMPLETE ***
*** Repair soft top hole *** COMPLETE ***
*** Replace hooks w/ D-rings *** COMPLE*** Replace plug wires *** COMPLETE ***
*** Repair turn signal switch *** COMPLETE ***
*** Replace windshield wipers *** COMPLETE ***
*** Rock lights *** COMPLETE ***
*** RTI ramp *** COMPLETE ***
*** Seal firewall holes *** COMPLETE ***
*** Seal fresh air vents *** COMPLETE ***
*** Seat belts *** COMPLETE ***
*** Secure EEC *** COMPLETE ***
*** Secure fuel shutoff switch *** COMPLETE ***
*** Secure pitman arm *** COMPLETE ***
*** Sell bumper *** COMPLETE ***
*** Sell radius arms *** COMPLETE ***
*** Shift indicator cover *** COMPLETE ***
*** Shift indicator pointer *** COMPLETE ***
*** Side mirrors *** COMPLETE ***
*** Spare key *** COMPLETE ***
*** Steering box brace *** COMPLETE ***
*** Steering stabilizer *** NOT NEEDED *** (installed ram assist)
*** Steering stops *** COMPLETE ***
*** Stereo speakers *** COMPLETE ***
*** Sun visors *** COMPLETE ***
*** Sway bar *** NOT NEEDED *** (Used nitrogen shocks instead)
*** T-bird calipers *** COMPLETE ***
*** Trailer light wiring *** COMPLETE ***
*** Tranny cooling fan operation indicator *** COMPLETE ***
*** Tranny kickdown (Lokar) *** NOT NEEDED ***
*** Tranny temp unit *** COMPLETE ***
*** Tranny vent *** COMPLETE ***
*** Twin stick *** COMPLETE ***
*** Verify Bronco garage clearance *** COMPLETE ***
*** Verify engine component castings *** COMPLETE ***
*** Verify exhaust size application (2.25"?) *** COMPLETE ***
*** Verify rear axle specs *** COMPLETE ***
*** Volt meter gauge *** COMPLETE ***
*** Winch cab controls *** COMPLETE ***
*** Wiper cover *** COMPLETE ***
Chuzie's monster transformation - jollygrngiant - 01-14-2011
Who needs sunvisors.......Wear sunglasses..duh!!!!
Chuzie's monster transformation - chuzie - 01-14-2011
Or just ride in the shadow of your rig!
Chuzie's monster transformation - medwards01 - 01-15-2011
chuzie Wrote:So I came up with a list of a FEW things I need/ want to do to the Bronco. Figured I would share.
Dayum Chuzie, that's quite the list!! Instead of making my own, mind if I just use yours? Now, if I just knew where to start....
cratchhe:
Chuzie's monster transformation - scbronco - 01-18-2011
you pilots have entirely too much time on your hands...:thefinger: Just kiddin, maybe... seriously, i would talk you into a frame off, but then i have often asked myself what pocessed me to undretake such a thankless task, with no logical answer... so anyway, jsut drive it and smile!