09-22-2010, 02:24 AM
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
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.
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.
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.
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.
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.
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)
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.
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
'77 351w- Explorer EFI, 4R70W, 4-link, lockers, 4.56, 35" MT/Rs with a severe rock addiction.
mokin:
Roads? Where we're going, we don't need roads.
![[Image: sig2.jpg]](http://i288.photobucket.com/albums/ll176/mchuzie/sig2.jpg)
mokin:Roads? Where we're going, we don't need roads.
