Chuzie's monster transformation

[chuzie]

Day 6 (2 Sep 10)

Objectives for today:
1. Install 4-link frame mounts
2. Install coil towers and place weight on the axles
3. Install driver’s rocker guard
4. Install shock hoops

Today was supposed to be a big day. We kicked it off where we stopped on the last work day with the 4-link frame mounts.

Upon arrival, I decided to take one last set of measurements; just to make sure everything was in place where it was supposed to be. We spent quite a bit of time the day prior determining ride height, pinion angle, and wheel base. I realized that during all those measurements we never verified that the lower spring cup mounts were level. With this in mind, I placed a level on the mount (forward / aft) and found it was angled low. This led us to discover the jack that that was holding the pinion in place had lost pressure overnight. We had to assume our previous measurements were in error and started over. I leveled the cups, verified the pinion angle (20 degrees), and then the wheelbase measurement.




After that, I began to adjust the links to determine where I wanted to tack weld the frame mounts. The best way to do it was first run the heims out 3 turns as a baseline to allow for adjustment and install only the lower links in order to slave the mounts to the frame. Once on the frame, the mounts we a good distance from the upper links at their current length. To install them, I had to run the upper links out to 14 full turns. Since the upper link max is 20 full turns before the heim separates from the link, I was a bit concerned but the tech guy at Duffs assured me it was ok.

I found it really helps to use tape on the heims, lock nuts, and links for reference points when trying to keep track of positions and number of turns. I made a lot of adjustments and made sure to record each to help expedite the process. There were a couple incidents where I lost track though and had to reset the entire system. This was necessary to ensure everything was the correct length.

I finally found the null where the links were of proper length, the wheel base was maintained, and the pinion angle was correct while maintaining level spring cups.



Next, we tacked the frame mounts and moved on to the coil towers. Objective 1 complete.



We had do determine where the upper coil towers were going to be placed. We referenced the James Duff picture below for a baseline which shows the tower to be almost to the bottom of the frame.



We cut out some of the lower lip of the body to make adequate room for tower clearance.



To make life easy we employed the laser level to mark the position for the tower which we centered on the lower cup. The towers were tacked in and the springs installed. Once the springs were installed, we transferred the weight of the Bronco from the jack stands to the axle. We took measurements to determine if the desired ride height met our target which was in the ballpark of 0” to ½” above the front.



Unfortunately, our measurements showed the rear to be 3.75” above our target. This would not usually be an issue as it can be easily corrected by raising the height of the coil tower to lower the ride height; however, the clearance from the top of the coil tower to the floor was only ¾”. How do we lose 3.75” with only .75” to work with?

The initial reaction was to cut some of the rear coil to match the front, but we determined that it was necessary to contact Duff’s for guidance since this is an out of the box “bolt on” application and cutting of the coils should not be part of the process.

Duff’s suggested we verify the spring model numbers on the front and rear in hopes they had mistakenly sent us a set of 3.5” front coils instead of 5.5”. Further investigation revealed the front coils were correct at 5.5” thus leaving no reason for the excessive rear height. Their tech folks are off for the holiday weekend so we will not receive further guidance until Tuesday of next week on how to remedy the situation.

We considered what the impact of my front bumper may have but Duff’s said it should not matter to that degree. More to come. Luckily the parts are installed and Objective 2 is complete.

Since the 4-link project had come to a grinding halt and we had received the new nutserts for the driver’s rocker guard, we took the opportunity to try and reinstall the part. The holes were still a hair too big so were we not able to tap them in as suggested but they did seem adequately tight after installation, so we pressed forward.

We ran into the same issue with the backing strip as on the passenger side with the strip being too tall to fit between the rocker panel and the guard. The only solution this time was to cut off about ½” from the backing strip with the plasma cutter. I hate we had to, once again, modify a part that would never fit to begin with, but really we had no other option. Once cut, the guard was installed and objective 3 is complete.



The front shock hoop issue has been potentially resolved. Duff’s suggested we cut the ears off the frame mount section of the hoops to eliminate the problem of the spacing being too large or small, and leave only the vertical portion for welding to the frame; once again, modifying a bolt-on part. As a result of my complaint, they investigated and found their fabrication equipment to be damaged and required replacement parts which is estimated to take 5 weeks.

We decided to call it a day so objective 4 is incomplete.

I am now on a 10-day government ‘vacation’ so the project will have to wait until my return.

Day 6 complete.
Objective 4 incomplete
Man Hours worked: 10
Total Project Man Hours: 52
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