Project "Big Country" - Front Bumper Fab

[SC74]

Here are a few shots of the interior of the tub with the new black bedliner. We went ahead and got all of the door jamb to tie it all together and make things easier.

I really like this black material a lot better than the gray!

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We got the tub from Keith's house to mine this morning and got it ready to go on the frame. There were a few last minute things we had to get done on the frame before lifting the tub - more clamps on the brake a fuel lines, cut the t-case shift rails for the twin stick shifter, and redneck trac-bar (two ratchet straps since we have not welded a trac bar in yet - waiting on final ride height first).

This is the first time that the chassis has been rolled so far as out of the garage in over a year and even longer since the frame has seen daylight! upergrin:

Here are some pics as we are about to get ready to lift the tub onto the chassis.

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Finally, the body goes back on the frame upergrin: :beer: :rebel: :rubeyes:

I have looked forward to this point for so long now and it's finally there! I can't explain how excited I am that we got this done today.

There are some minor kinks to work out, but regardless it's on!!!!

It's super high, but we're going to do what we can to get it lower. Right now the windshield frame is just over 7 feet tall. Keep in mind I'm 6'3" and the top of the bed rail is shoulder height.

We're up against several restrictions on what we can do - mainly the fuel cell and the AN fittings coming out of the top. There's going to be some more fab work (cutting the bed up and making a "hump") to get it lower, but we're going to do the best we can with what we have to work with. The channel at the rear of the under-body is screwing us up too - can't go any lower than a 2" body lift without cutting that channel and sacrificing body strength. I've got the 1" body mount lift and will add another 1" of body lift to that totaling 2" body lift.

The coils are 5.5" EB coils, but they are mounted on top of the Cage arms. The Cage arms are aprox. 2" higher than the stock coil bucket height, so really there is about 7.5" of lift. We may end up cutting a coil or two out of the coils to get it down some.

The rear is not set in stone at all either - there is only tube tacked to the axle and frame holding the rear up and level with the front for now. Once things are finalized, I'll measure and weigh it for the right coil-overs.

No matter what, I'm super happy about it :chili:

Here are some pics of it ... oh yea.... Trigger can still jump in the tailgate! Not a running jump... straight vertical jump cratchhe:. He's got more hops than I thought :bdent:

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I bet Robert breaks out the rattle cans of Kubota Orange to make sure it looks good.

Keith was right - I had to do a test strip just to see how the orange looked against the black. I like it upergrin:

[cuz1]

Impressive, It sure is coming together. :biggthumpup:

[Mill Knob]

Look greart Robert... Man the little things that make use happy.. Keep us posted....

[broncomania]

that is lookin good. nice work.

[SC74]

Here's my problem .... I've got to run at least 2" body lift to clear the body support channel under the tailgate. I would need at least 3" to clear the AN Fittings. I'm trying to limit the BL as much as possible due to the high suspension already. cratchhe:

Here's what I'm thinking ... I want a tool chest in the rear of the Bronco. I've got my eyes on one at TSC that will work perfectly. If I cut a hole in the floor for the AN fittings and the cut a hole in the tool box I should be good. I can bend some aluminum to cover and protect the AN fittings inside the tool box. That makes them out of sight and out of mind I hope upergrin:

Any other ideas??

[blazinchuck]

if you dont want a BL, I think that will be the only option.I like the idea. I think I would have the box modified by a tig welder, so nothing at all could possible hit or damage the fitting inside the box. Just cut a small square section out of the box and make a smaller box to cover the fittings, then weld it to the truck box...so it becomes a raised portion of the truck box. just a thought,Chuck

[SC74]

if you dont want a BL, I think that will be the only option.I like the idea. I think I would have the box modified by a tig welder, so nothing at all could possible hit or damage the fitting inside the box. Just cut a small square section out of the box and make a smaller box to cover the fittings, then weld it to the truck box...so it becomes a raised portion of the truck box. just a thought,Chuck

Exactly what I was thinking - a box inside of a box. I've been debating buying a spool gun for the mig and this might be the perfect "reason" to buy it. Keith has a TIG but it's not high frequency - go figure cratchhe: If anything, I'll at least pop rivet the heck out of it and put some silicone to seal it up good.