Chuzie's monster transformation

[broncosbybart]

Found out the other day my foot is fractured in multiple places. Joy!

Crap dude. Did Albemarle's finest totally miss that? Sounds like a far cry from sprained ligaments.

[rtj731]

Not sure how they got there though. Maybe to much fatigue from frequent power applications???

So what's the story on the four link, the leaks from welder or design/both. I am thinking on doing the duff 4 link but was waiting on your experience and recommendation/s

Sure hope the foot heals fast been there done that. Don't know your outfit but if you could find your way into the spec op clinic (MacDill) I'm sure you will get some good advise

[chuzie]

It is only 1/8" metal on the back cover so I too am thinking a combination of welder / power application and fatigue.

We tried to braise it but it keeps leaking. I think the next step will be JB Weld. I really see no reason to have those two supports welded to the back cover and question why they designed it like that in the first place.

Anyway, that leak is the least of my concern. I think my rear main bearing on the 5.0 may be going south. More to come when I get back from my mission next week. Either way, I don't think it is going to be good. Looks like the end of 2012 is going to be extra crappy for me!

I will post up info on the bumper and the 4-link/ shock results in a couple days too.

[Casey835]

Dang man I hate to hear all that! It is not just as simple as getting another axle housing either. Top it all off with the main bearing also.

[broncomatt]

Wow, cant belive that luck. If you know some one with a tig welder its an easy fix. The mig can do it too but it takes more time.
Whats up with the rear main? Noise?

[chuzie]

Wanted to share the badass bumper Chuck and I built a few months ago before URE. Sadly, I am just now getting around to posting pics.

The bumper is 1/4" plate with reinforcements along the back as well as in the terminations at the corners. The sides were heated and bent and turned out super nice! We also went the extra mile with the hitch and secured it both through the front and the rear plating for added strength. I doubt and rock will stand a chance at touching this bumper.

The tire carrier is super stout too. We used two heims for the swing pivoted on a single bolt housed in DOM secured by both the upper and lower bumper plates and then supported by a second piece of DOM secured in a similar manner. The carrier is all 3/16" rectangular. My tires are super heavy and this carrier does not budge at all!

We left extra room on the swing for future upgrades like gas can or hi-lift. I still need to finish closing up the back side to prevent mud from entering. The jack points need to be cleaned up as well. The die grinder did not do so well with the 1/4" steel! I plan to install 2" LED reverse lights in the flat rear face as well.

It weighs 130 without a tire.

I would say it took us about 30 hours to do all of it and maybe about $200 in materials. It was a LOT of work doing something like this from scratch, but I think is was well worth it.

Just want to say thanks to Chuck who did an AWESOME job helping me. Well, maybe I helped him. Dude does amazing work when he actually puts down the Mellow Yellow long enough to run a bead of weld. upergrin:

[blazinchuck]

maaaaaaaan, you know its all good. see a need/fill a need lol

im impressed...and very happy with how it turned out...we learned a lot, luckily we worked every idea out before welding every single part and screwing up.

[chuzie]

UPDATE:

I fabbed a set of lower shock mounts using .250 wall 2x2 and welded them below the axle tube to eliminate the lower tabs on the truss. They are super stout so I am not worried about them hitting rocks. Installed Skyjacker M95 monotube shocks on the outboards and left the Duff's hydraulics on the inboard positions.

THIS IS A COMPELTELY DIFFERENT BRONCO!!!!

Corners like a champ, much less lean, super stable, better traction, super extension and compression and overall a much better experience.

I really think 4 hydraulic shocks for this system is just too little for the demands we place on it. What I have now is a good combination but wonder if some nitros in lieu of the hydraulics on the inboards would be too much.

Anyway, I am also thinking about getting another set of monotube shocks for the front and am willing to bet they will eliminate any need for a sway bar.

The Duff's system is good buts needs some tweaks. No one has yet to figure out why we had to jam the upper coil mounts so high above the frame to get the body level. That is what caused this mess in the first place. Oh well, I guess I just got the luck of the draw on that one.

If I find my new RTI score I will be sure to post it. Just not sure where I misplaced it!

[SC74]

That rear bumper is badd-ass! I can believe it took every bit of that time with 2 people. I'm sure you'll get a lot of compliments on it and I may even steel an idea or two off of it.

On the shock mount, that's the thickest .025 wall I've ever seen!!! :hysterical:

[ncsubronc]

bumper looks slick...nice work chuck/chuzie:bigok: