BroncoBilly EB build up

[CORE 4WD]

Ok, here's the next project in line. Goal is all-around Paragon/Tellico/Crozet trail beast, shake-down in June (Crozet), hit Annual this year-

Full width D60 front, Detroit 4.88


Jeg's 351w, Atlas 4.3, C-4, will have M/M 12000 installed-


10.25 rear F/F, Detroit, 4.88, 23 gal tank-


It's going to be a busy April...

Ok, so now it's June. Better late than never!
The EB is here and we got some stuff done today-
Yep, it's too tall with the top on. Needs to come off for gutting of interior anyway-


It doesn't look like it clears but it clears easily-
Got the top off, thermostat housing on right, new fan switch hooked up, flares off (going to install Wild Horses Warflares), removed rear bumper, removed rear seat and started stripping undercoating from inside to clean and prep for real rust protection (Line-x). That's one happy dude!


Ok today we did this-
Added 2 chamber Flowmasters with turn downs to get exhaust toned down, semi-mocked up, may have to go with shorty headers-


More scraping of interior and fixing a couple of coolant leaks, troubleshot charging system, (more work) and then had a little fun. Drove it around my loop and played on the ramp. We're changing out front springs to James Duff progressive rate and rear to Deaver's 11 leaf, should flex a little better. Getting ready to order front driveshaft once we pop in ne front springs.-










Pics added june30, 06-

Torched/ground off stock shock towers and now just need to drill mount holes for shock hoops-


Added July 1-

Pic of both EB's-


Josh (brokenxj) and Billy bolting on protofab rear bumper-


Bumper on, now that we know it fits we can make a couple mods, prep and paint-


Rear shot of both-



Still need to hook up heater motor, wiper motor, emergency flasher switch and order shocks that were measured out today on ramp...

Pics added July 11th-

Bumper on, need to weld on winch bar (obviously needs paint, too!)



Pics added July 16-

winch bar added-




Lower rear shock mounts tacked-

May not be going with this shock, need to ramp it again-



Pics added July 20-
New James Duff Progressive rate springs in front with long travel (15") 70/30 shocks. Rear shock mounts that were tacked have good angles, they'll get burned in. Re-did ram mount, no more tie rod tweaking -




Cutting hole for hood scoop. Nothing like putting a big hole in good sheet metal! It needs the ventilation actually-



Mounting scoop-


Hole saw works great-




Pics added July 27th-
Remember Chad Smith (green Nissan Hardbody)? Installing new water temp guage-

Marking for flare cutout-

Starting cut for Jim-

Jim63 getting a crack at it-

Rear cut-

Cutting spacer brackets for tranny cooler which will mount to passenger side fender well. We'll be adding a heat shield for headers and probably do a vent under it as well for outside air. Stick a guage on tranny and see how the temp does-



Yea it going to get painted -

Rene's friend's son Justin cleaning up some wiring before mocking up oil cooler brackets. Notice clock. That's P.M. Hey I never said staying with me and Rene would be a free ride!-

Justin eyeballing the tach for me while I check alternator outputs to batteries-

Billy's son Shane having a little fun-

You never know what you might find in a glovebox. This is going to be fun heh heh-



Pics added August 2-
Sanding begins-


Pics added Aug. 11-
The flares are going to sit flush with body seam so we're doing away with the fuel inlets on the body. No aux tank anyway. The filler will be hidden and retained with a spring and safety catch.-
Cutting and fitting patch for fuel filler port holes-

Tacked-

Ground out and waiting for metal paste and body filler to smooth out imperfections-

Cutting aux tank patch-

Going here-

Clamped-

Welded-

This was done with Campbell-Hausfeld Utility welder, no gas by the way. Seemed to work well.


New pics 17 Aug...

New SVA-Performance (Ontario Canada) 210 amp alternator. 100 or so at 800 engine rpm, 210 max. The other one Load Boss, put out at too high an rpm for running two electric fans at idle, around 1200-1500 rpm's. Thanks RRRAAAYYY2 of "classicbroncos.com"! ;D

Easy hook up, green and red wire is switched 12 volt exciter wire then hook up alternator cable-


Truly bolt on for 351w, otherwise you'd need a spacer-


Got rid of Painless switchable relay set up and wired batteries in parellel. Got double the amps and alternator charges batteries as one. Both batteries are new, recommended for wiring like this. All tied together with 1/0 welding cable. This setup seems to work great over the other setup, fans don't drop at idle and volt guage stays up vice dropping waaay off. Moved radiator forward for SPAL fan/water pump clearance also. Still need to clean up engine bay wiring, build better battery restraints etc-


Pics added 29 Aug-

Rocker sheet metal removal-
Taping cut line-

Could be good Caption Contest fodder I suppose (my angle grinder died on me, this works too)-

Billy getting his licks in too-

What do the inside of YOUR rockerrs look like?-

Going to steel supplier tomorrow for slider material. The cage will be tied in to frame also. I think it will get over some rocks now-



Pics added 31 Aug-

Started building rock sliders. They will include a sill support and one roll cage support. 2"x4"x3/16". Wanted one 2"x5" but they didn't have any in and I didn't want to wait so back to back 2x4 it is-

Notching inner end. Should have just made inner piece shorter from the git-go but whatever-


Mocking-

Ends will be angled to match flare ends-


Pics added Sept 9-
Drilling frame brackets/frame mount holes-

Tapping-

Mounted-

Sill support is top bar 1/8th wall-

Drilling sill/sill support bar-

Tapping sill support-

With sliders mounted under sill and a little help from jack to level out, the frame tie-in's can be made-

Cardboard template was used. Tie-in's are same angle in case we end up wanting to do rock plates-

Bracing-

Ends will get 45 degreed and capped-




Pics added Sept 11-
Marking for angle cut-

End cap ready to weld on-

All end cap welds will get ground out and smoothed-


Pics added 26 Sept-
Bed is sand blasted-

He laughs now-

Nice floor pans-

'Nuther pan shot-


Pic aded 30Sept-
Floor pans are here, time to get busy (er)!


Pics added 03Oct-
Cutting out floor-

That was fun!not-

Need to clean pan supports and paint then add seam sealer, drill holes and shoot rivets-

Driver side next-



Pics added 04 Oct-
Need to add 3" to top of pan. Saved hole metal from hood scoop-


Spot welding. Used hood metal as a heat sink to avoid blow-through since I'm just using .030 flux core. Welded top and bottom, top is ground somewhat smooth, Rhinoliner will cover anyway-



Floor supports are now ready for pan. Hey now I can drill and tap top of frame rails for third rock slider bolt. Saaweet-

Pan ready to get sealant and rivets-


Pic added 22 Oct-
Pans are in, it's going to Production offroad tomorrow for Rhino lining yea life goes on-



Pics added 02Nov-
Production Offroad's booth, now that's blue-

Primered grill-



It will be back at my house tomorrow if anyone wants to check it out in the eve...

Pics added 03Nov-
Back from Production-
Scoop-

Goin' together

Putting the grill back together-

Link: <a

Drilling for flares Shayne and dad-

It's close-


Did some knick-knack stuff tonight, correct bumper hardware, passenger seat (although the cage will be ordered Monday and the seat is actually going to be attached to that)-



Broncos rule

Drove it back from Big Al's after swapping to shorty's, they did an ok job

Pics added 15Nov06
We picked up a trailer on the back road from Hatteras, talk about a killer surf trip-


Fabbing an e bracket system-


Almost ready to "rock"- pick up front drive shaft tomorrow, cage is on it's way from Cali-



E-brake fab-
Equalizer bar-


It's late so what. Riveting on original cable bracket-




I'll stick it on the ramp tomorrow to make sure the driver's cable is long enough-


Pics added 16Nov-
Front driveshaft is (finally) in, Standard parts 1350 axle end, 1310 t-case end, long spline thick wall-



Pics added 19Nov-
T-case skidplate fabbing-
Starts with a nice fresh piece of cardboard-

Take measurements and get out the scissors. Fitting, measuring, bending and cutting as needed-

Test fit is good-


Tranny will get one too-

Gotta get some 1/4" plate now...

Pics added 20Nov-
Ok, 3/16" will cut it I think-
After marking from template, plate is scored with 4 1/2" angle grinder with cut-off disc (don't go too far- but if you do, hey it's steel, weld it and smooth it!)

Ramp comes in handy again for bending-

Trial fitting before welding-

Weld up the scores, I put a little pressure to help retain the shape-


Pics added 26Nov-

Poison Spyder diff guards-



More t-case skid work-
Use shims to maintain gap-

Fitting for mount tabs (passenger side)-

Got tabs on, now fitting for mount holes-

Front cover-

Another rear shot (with proper brake lines built)-


Protofab cage is here and going in yee-haw-

Seat mounts, Alex will be helping measure in the a.m. (he made me promise I'd wait for him!) then off to Jack's (JR Enterprises)I'll be adding gussets and more triangulation sometime, just seatbelt tabs and front/rear seat mounts for now...


Chicken bar-





Seat mounting begins-

Contouring mount ends-





Got some more stuff done on seat mounts today-
Bracket holes-

Tacking on seat back latch-

Factory seat mounts have a right side drop bracket to floor. Mounting to cage is flush, more or less, so I made one to match the left side, which is flush. The seat folds forwards as seen-


Pics added 12Dec06-
Jeff's Bronco Graveyard anti-wrap bars. Couldn't do'em much cheaper so we just ordered these to save time. Ramping tomorrow to check flex and fit-
Spring mount-

Front mount-

Front mount for hole template-

Shayne (Billy's son) installing bushings into control arms-


Installed, u-bolts need trimmed, looks hack-



By leaving this jam nut loose the control arm will twist with axle movement-



Pics added 15Dec06-
Rollcage painting-
Prep-

Rattle can primer-




Pics added 17Dec06-





Pics added 21Dec06-

Gotta have a drain-




Pics added 27Dec06-
Roll cage is installed, it will get tied in to frame this summer-
Rear sandwich plate-


Mid sandwich plates-


Bolts to this-



Got all the seats and front seat belts in too-
Seats are getting Wet Okele covers (Billy sez thanks Katy- I mean Santa!)-
I added these mounts to cage along with seat belt tabs-




Happy New Year's Day!
Ratchet shifter install-
Remove stock levers-

Neutral/back up switch-

Drill/tap roll cage for mount plate-



Alex getting some action-



Install B&M lever-

Adjust cable-



Bling-






Pics added 16Jan07-
Twin stick boot and custom plate is now installed-



Pics added 17Jan07-
Down to little stuff (except re-positioning the driver side wedge)-
A little more bling-


Bye bye crusty busted up blinker pads. Polyurethane blinker pads-




Parting shots from my house-

Tailpipes need to be bent out of the way of shackles so the rear tires will stuff up better -




Now to get some real action shots, no more poser junk! Have fun Billy! It's alive...

Pics added 29Mar07-
Correct track bar mount bracket from Wild Horses Early Broncos. Makes a great place to mount the hyd. assist ram end too-
Front-

Rear-

[Chele]

Looks great!! Has it come home yet?

Can there be a theme?? Can we call it Beast and paint it blue (like the x-men) ;D

[CORE 4WD]

chele said:

Looks great!! Has it come home yet?

Can there be a theme?? Can we call it Beast and paint it blue (like the x-men) ;D

I believe we can call it a beast and yes- it IS getting painted blue with green trim to go with his business's color theme! Earthworks, Inc Landscaping. It will be home at the end of March finally...

[RuffRider]

That is gonna be a bad az truck.

[RuffRider]

Heard it's back. So expect it'll be CORE4WD soon..

[Jim63]

dang that looks sweet! I am digin the paint job

[RuffRider]

Yeah too bad. I don't know y he wants to repaint it.

[Jim63]

what ever color it turns out to be its going to be one bad bronco!

[CORE 4WD]

Pics added at top June 21 '06

[swampercj]

Nothing like an old Bronco. I didn't see it at Crozet this past weekend on Sat did he run it on Sunday?

[CORE 4WD]

Not ready yet. It doesn't have upper shock mounts, rear lowers, front driveshaft, skids, sliders, new engine and gear break-in, etc etc. Lots of tweaking to do. Crozet will be the testing ground soon, Scott! Somewhere before the Annual, shooting for mid-July. Maybe be ready for Annual Picnic? I have a score to settle with the hill on Trail 2! (I was denied in my XJ so I gotta bribe Billy to let me whump it with his junk!)

Dave

[RuffRider]

Finally, it's there.

Ditto on trail 2

[87B2XLT]

I'm curious if the stock axles were already parted with..... Looking good so far, though ;D

[Chele]

ruffrider said:

Ditto on trail 2

What was wrong with trail 2??? ;D ;D ;D ;D ;D



And..that thing is huge.

[RuffRider]

Uhhh, some of us didn't make it up 2.... like you did. I call it a personal vendetta that'll last until we run the Annual J/K