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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[blazinchuck]

im gonna get out there and do something since your on vacation lol

[blazinchuck]

i was able to get the front hoops installed and tacked into position. working on the rear shock mount for the frame.

[chuzie]

get away from my rig!

[blazinchuck]

get away from my rig!

[SIZE="6"]meh[/SIZE]:hysterical:

[medwards01]

Chuck, sounds like somebody's a little jealous that you are wrenching on his rig while he's away on his "guvmint" vacation....:rockon: Working on EBs rock, especially when it's somebody else's money :rockon:

[blazinchuck]

BTT...this is some great weather to be wrenching on a bronco...Chuzie, get your arse back in town and lets get busy again!!!!!!

[chuzie]

Day 7 (16 Sep 10)

Objectives for today:
1. Finish fitting rear coils
2. Finish shock hoop install
3. Begin new fuel system installation
4. Install receiver hitch

This is the first real work day since I have returned to the country. The main issue today was to resolve the ride height problem that arose a couple weeks ago when we first attempted to install the rear coils. I spent a couple hours on the phone with the James Duff techs trying to determine what was causing the rear to be 2-3” higher than the front. The first thing Duff’s wanted me to do was remove my massive front bumper and winch just to make sure their weight was not dramatically lowering the front and raising the rear. I removed the bumper and winch and, though the front lifted slightly, it was not nearly enough to fix the ride height issue.
We swapped many measurements trying to find the culprit in the system. We measured coils, both compressed and uncompressed, the height of the coil buckets and towers in relation to the frame, and even eliminated the front coil towers from the suspect list. We determined that it would take about 300 pounds of weight in the rear of the Bronco to get it to level correctly.

The only thing we could come up with is to try and change out the rear coils for another set just in case the current set was a bad. Now we did measure them and the measurements did check out, but we feel like it is necessary in order to fully eliminate the coils as a player just in case they are not compressing correctly. They are slated to arrive tomorrow via UPS so we should have an answer soon. I fear that the last resort, if the new coils do not work, will be to cut them to adjust the ride height. Objective 1 incomplete.





The shock hoops have also been a lingering issue awaiting resolution. Chuck worked on them in my absence and managed to beat them into submission to the point where the tabs hugged the frame enough for a good weld. The only tab he had to cut was on the front upper passenger side. Today he finished welding them to the frame and we painted the mounts black. The driver’s side was then fitted with the dual shocks.


The shocks gave us quite a fight due to the tight fit between the hoops and the bushings. We lubed the bushings and had to beat the shocks into place with a mallet. In retrospect, it would have been much easier if we aligned the shocks in the upper mounts before we installed the hoops. Since we ran out of time, the passenger shocks will have to get installed tomorrow. Objective 2 complete, less the shocks.






The old fuel system was mounted inboard of the driver’s frame and has to be removed due to the installation of the 4-link mounts and radius arm mounts. The plan was to just move it up higher than the frame parallel to its previous position. After much discussion, we decided to install the fuel lines, rear harness, and possibly the brake line inside the driver’s side frame to keep it protected and out of the way.

New fuel lines were fit and I relocated the fuel accumulator and high pressure pump from the rear, near the gas tank and low pressure pump, to the engine bay so the high pressure pump does not have to work so hard to push fuel to the engine. Plus, the relocation means I would not have to use as much expensive high pressure EFI line. It turned out really nice and the HP pump fit quite well under the old tire jack clamp on the wheel well. We are waiting to relocate everything to the inside of the frame until we finish welding the frame mounts for the suspension. Objective 3 complete.



While I was out of town, Chuck started to install the receiver hitch. He ran into a lot of resistance with it not fitting correctly and had to trim a lot of the frame between the frame horns to just get it to slide back far enough to line up with the bolt holes. Since the hitch did not come with any hardware, L, the installation is pending the purchase of ½ hardware for completion. Objective 4 incomplete.



Day 7 complete.
Objective 1 and 4 incomplete
Man Hours worked: 8
Total Project Man Hours: 60

[josephitguy]

Looks like that hoist is bending a little picking up that bumper :hysterical:
We have been anxiously awaiting progress, good job! :beer:

If you make me a strong enough seat in the back I can 'level' it for you in the trails cratchhe:

[Timstrk]

Wow, Mike. That looks so much nicer without the front porch and rocking chairs ahead of the grille. Might consider using that as the anchor for your trawler.

Tim