im simply copy-pasting stuff voer to here... the full thread is here (http://www.fullsizebronco.com/forum/showthread.php?t=118622&page=2)

i threw a rod in the bronco's 351w... truck was removed from DD status... now the fun begins: enjoy

this has gone way too far lol.. enjoy guys.. im taking it all the way

Im fully rebuilding the truck...top to bottom.
heres what we are starting with:
91 Bronco : 351w, e4od, BW1356
D44 Solid front, cage arms, superflex 6inch coils
8.8 rear, leaf sprung and shackle flipped
4.10's two lockers, and 35's

Heres the main plan:
*351w F4 block(full roller) bored and stroked to a 393w. gt40p heads, edelbrock manifolds. Mounted w/ autofab motor mounts
*4r70w: will shorten the driveline 8 inches and wont have the issues the e4ods have
*NP205.: Im on my 3rd 1356
*New Front and rear driveshafts. Both double cardian. 1350 joints or higher...most likely .25 wall
*14 bolt rear. ARB or Detroit. 4.88's or 5.13's. Shaved and trussed
*D60 Front(if i can find one for a reasonable price) if not 8 lug outers for the 44.. selectable locker and matching gears
*Front suspension is retaining the CAGE arm 3 link.
*Rear Suspension will be a double triangulated 4 link.
*Suspension will either be using superflex coils at all four corners. Or FOA 14-16inch travel coilovers... the cost is near equal between the 2.
* Frame is being sandblasted now. Will be fully boxed and re-enforced... All crossmembers will be replaced with beefy ones, new engine xmember, trans xmember and a few new xmembers
*38's or 40's


Other modifications being done:
*Gas tank raised through the floor to increase exit angle..
*New front and rear bumpers
*Fiberglass fenders...allowing me to tuck the larger tire and lower the truck 1-2 inches
*92-96 front clip swap
*new seats for interior... eventually a cage too
*winch
*mojave style heater plumbed through frame rail and installed in back of truck

...yea thats all i can think of right now...

pics start below

heres my FREE 4r70w... buddy is giving me the 4wd output shaft and tailhousing i need too.. another friend is rebuilding it for a case of beer... :D
http://www.supermotors.net/getfile/616229/fullsize/engine-trans-001.jpg

Heres the FREE F4 block from the same guy...ryan can tell you what these are worth with a clean bore.... going to the hot tank this week and getting bored and new cam bearings popped in...
http://www.supermotors.net/getfile/616232/fullsize/engine-trans-004.jpg
the dogbones and keeper and some other misc stuff from it in the parts washer
http://www.supermotors.net/getfile/616230/fullsize/engine-trans-002.jpg
and the frame that just got loaded up and is heading to a friends to be sandblasted...
http://www.supermotors.net/getfile/616231/fullsize/engine-trans-003.jpg

enjoy:D

okay sorry for the delay... heres some pics

frame... fully sand blasted...
http://www.supermotors.net/getfile/617580/fullsize/frame-005.jpg
http://www.supermotors.net/getfile/617581/fullsize/frame-006.jpg

here it is fully wiped down with oil... paint would have been fine... id rather do this... it was free, quick and cheap... as far as clean up... i really dont think it will be that hard to clean... a few cans of brake clean or some acetone will get all that off
http://www.supermotors.net/getfile/617589/fullsize/frame-013.jpg

started replacign rear xmembers

pics

heres the two new xmembers in the frame... 5" C-channel... leaves a 3/8" gap at the top...ill fill it and the box will support the top edge... the rails are parrallel and perpendicular to the xmember... it straight i promise... i gave myself .5* tolerance max
http://www.supermotors.net/getfile/618515/fullsize/frame111-001.jpg
plenty of penetration to the rail
http://www.supermotors.net/getfile/618517/fullsize/frame111-003.jpg
one of the welds... prolly too hot
http://www.supermotors.net/getfile/618518/fullsize/frame111-004.jpg

oh and heres a pic of the new shop were in... we have another lift... just not sure if we are gonna put it in yet
http://www.supermotors.net/getfile/618519/fullsize/frame111-006.jpg

tonight im gonna try to get most of the third in xmember done... im short on steel though

enjoy

dc

so now ive got my 3/16 plate all sheared up and was getting ready to do some boxing today... ive ran into an issue

for one, the two(four total) rear most body mounts sit on top of the frame... rather than outboard like the others...

second, i still have the issue of coil/coilover clearance with the tires in the rear... because the frame is so wide...

so as i sat there and thought about it one option came to mind...
im gonna cut the back tail sectio of frame off and re build it with box tube... i will also narrow it

that way, i gain the clearance i need for outboarded coils/coilovers... and i can simply build an outboard body mount for the rear two mounts...

the only issue it creates is fuel tank... which isnt too bad

there might be pics later

UPDATES FINALLY!

got some work done tonight... yea 100% by myself... kinda stunk but i work best that way... managed to get the frame that high too lol


heres where i started...got the frame up onto the leveling stands i built... that was a PITA... got everything deadnuts level... when i say level, i mean straight and square... level as hell... this isnt a job for your craftsman framing level... i used my digital angle guage... max tolerance: 0.2*
http://www.supermotors.net/getfile/620397/fullsize/frame0327-008.jpg
heres the top of the levers... 7/8" all-thread, 10.5" adjustment each...
http://www.supermotors.net/getfile/620398/fullsize/frame0327-009.jpg
the cut mark all laid out... 90* straight down (no square here, use your angle guage)... made against this hole on either side of the frame... that way i knew they were dead even...used the cutoff wheel on the grinder
http://www.supermotors.net/getfile/620399/fullsize/frame0327-010.jpg
heres what i managed to rig up to catch the rear section of the frame since i was working by myself... two saw horses with some 3/16 plate... jackstands and a jack
http://www.supermotors.net/getfile/620405/fullsize/frame0327-007.jpg
AHHHHH NO WHAT HAPPENED!!!!??? lol... first cut made...:D
http://www.supermotors.net/getfile/620400/fullsize/frame0327-011.jpg

frame rails cut... if ya cant tell the location, those 4 holes on an angle are the front leaf spring hanger rivet holes... so its just behind the hangers...
http://www.supermotors.net/getfile/620402/fullsize/frame0327-013.jpg
its getting shorter... btw ignore the gangsta mobile in the background... not my project
http://www.supermotors.net/getfile/620403/fullsize/frame0327-014.jpg
crossmember removed...this is all thats left...the leveler jacks were there to keep things true and square...they are a must for this type of project
http://www.supermotors.net/getfile/620406/fullsize/frame0327-016.jpg
new crossmember in...made from same material as the new frame rails will be... 5x3 box tube...3/16 wall...prolly overkill..but its same thickness as the current frame and the right size... w/e its nice stuff
http://www.supermotors.net/getfile/620409/fullsize/frame0327-019.jpg
weld on one side...damn that looks good... i know you pirate boys need a weld pic lol... rag away
http://www.supermotors.net/getfile/620407/fullsize/frame0327-017.jpg
and on the other
http://www.supermotors.net/getfile/620408/fullsize/frame0327-018.jpg
another shot
http://www.supermotors.net/getfile/620410/fullsize/frame0327-020.jpg
overall current length... sorry about the welder in the pic
http://www.supermotors.net/getfile/620411/fullsize/frame0327-021.jpg

enjoy... hopefully i should have rear frame rails back by tommorow night

dc

the new frame rails will come directly off that crossmember... 31" apart (they were 37.5")
gusseted and reenforced

more tommorow

dc

got the rear frame rails done today... pics tommorow

dc

new d-side frame rail hung... just tacked in place... i didnt have a straight edge available at the time long enough to keep it parralell with the frame... thats the biggest challenge right now... its difficult to be sure
anyways... new risers welded in...30* climb like the stock rails were... they are 3-5/16 in board on each side... the stock rails maybe went 3/4" in board... so i gained a good bit of clearance here...
http://www.supermotors.net/getfile/621520/fullsize/frame0327-022.jpg
the inset
http://www.supermotors.net/getfile/621522/fullsize/frame0327-024.jpg
another of the inset
http://www.supermotors.net/getfile/621524/fullsize/frame0327-026.jpg
3 passes to the risers... approximatley 3/8 wide each...like my wavy right one... yea left hand baby
http://www.supermotors.net/getfile/621523/fullsize/frame0327-025.jpg

the outside of the origional frame will gusset to the risers... side and bottom gussets will hold it all together... it wont look like a sudden width change when im done...gotta hang the other frame rail tommorow if i can get some extra hands up there... make them parralell with the frame and zero them out... then finish weld... ill start gusseting that...

i need to tear the bronco down and get my other 351w in the frame for mockup...along with the 4r70w and the np205...
i still havent found info to tell me what it will take to mount the np205 to the 4r70w...ill go pick up the 205 this week... we shall see...

ive got a crossmember to add behing the tail housing of the tcase... then ive gotta figure out what im doing with the engine xmember and i can start boxing hopefully this weekend

dc

lol anybody interested

Liking the build thus far.keep the pics comin im watchin it.

hahah just hadnt heard any inout thus far lol... hopefully ill have the drivetrain mocked in this weekend and the frame boxed... im ready to have this chassis done and move on to motor and suspension

still lots to do...

I like it. I would love to have a fullsize bronco.
I am really interested in the 393. What rotating assembly did you go with?

I would have just cut the front fenders instead of going with the glass, what if they accidently touch a rock?

i havent purchased the glass yet... we shall see... id like to...but they are quite pricey and yes not designed for the trails...plus i hate the buttons they mount with... we will see

the 393w is sort of a budget build... the crank is SCAT cast. stock rods and a set of stock 302 pistons my machine shop found... final CR will be 9.7:1... stock was like 8:1 ... not 100% sure on heads yet... i may go with some gt40p's for now... i should have the $$$ for alumniums though... more on the motor soon

machine shop is bal;ancing the rotatting assembly and finishing the block this week

dc

I am really interested to hear about the motor. If I had a bronco(early or fullsize) your pretty much building what I had in mind.

If you go with the P head what header will you be using?(are there long tube's available for this)

I thought the 351 piston was a bigger bore than the 302? I also thought you had to bore the 351 to get you up in displacement. ( I guess it is more stroke)

the 302 and 351w both use a 4" bore stock... the 351w piston is like 1.7 or something tall... where the 302 pistons are 1.6... there are stroker 302 pistons that are super short deck like 1.3 ... those are the 347 pistons that used to be notorious for the oil ring blowing out...
the 393w is a 3.85 stroke crank with a stock 351w(5.965 rod)... the 351w piston would be above deck... im boring the cylinder to .030 over... you could run stock bore... it would be something like 387... which would obviously also work fine...
i was planning on using keith black #364 pistons.... they are hyperutectic with a 22cc dish...leaving me with about 9.5:1 CR with a 60cc head... however my machine shop had very bad things to say about the hyperutectic keith blacks...apparently a single ping or detonation and they start falling apart, pretty much fully fracturing...they said they know of at least 10 people who have destroyed those pistons in less than 2 years on NA motors... i dunno... but i walked away from them...
i was planning on a forged piston after that, however the $500 plus price tag wasnt so great... the machine shop found these factory cast pistons that im gonna use now... they are $130 a set which is awesome and will be perfect for me... this motor will never see boost or spray

Im still undecided on the gt40P's... i can get a set super cheap from a buddy and run them temporarily... they will feed the motor fine but i have a feeling they will run out of flow above 3500 rpms.... yes im building the motor for power right off of idle, however i dont want it to fall on its face above 3... the gt40p's have like 155cc intake runners... im shooting to find an aluminum with a 185cc intake runner... that should work nicely...
for headers i will probably be using ford racing SS headers designed for the truck... mustang headers designed for the gt40p's drop the collectors into the firewall so thats not gonna happen... a tubing modification needs to be made on the truck 351w headers to make plug clearance possible with the p's... its just one tube, pass side i think... theres a write up on it on another site...

just ordered some poly bushings for now... gotta mock the drivetrain in... i was planning to use the nice beefy autofab poly mounts, however im replacing the engine xmember with something lower profile, so he autofabs now have no where to mount...
ill make some custom motor mounts up, the drivetrain is also offset as you can see from the pics for the ttb diff and the 8.8... im gonna hopefully jsut center it with the 14bolt and hopefully it will line up nicely with the front diff... if not ill split the difference so they both will work...d-shaft clearance to the side of the trans is my concern...
gonna use the poly mounts to make a trans mount too because no one sells one for the trucks...
hopefully i can get some good solid hours into it this weekend...

btw i think im keeping the manual shift bw1356 for now... i have the 205... but the bw1356 has a lower low range...and i think its a plenty strong case for right now... i can always swap the 205 in later if i want...

dc

What cam are you planning on running in that motor? Something like a Comp Extreme 4x4 cam, 262/270 adv. duration, .493/.512 lift should give great low-mid range power. I've got an Extreme 4x4 cam in my Windsor and the bottom end punch is amazing.

Oh, and if your tricky with a die grinder those GT40's will make for an excellent off road head.

great to know man thanks...yea i hadnt picked a cam out yet... i converted to mass air so i have some options over the SD junk...
thanks

they are $130 a set which is awesome and will be perfect for me... this motor will never see boost or spray

dc

How about some more info on those pistons? I went with the Coast High 393 Kit, IIRC the compression ratio ended up being 10.5:1 with 64cc heads. When I build another one it will be in the 9:1 range, I have already destroyed one piston and get some pinging at highway speeds. Otherwise it is a bitchen offroad motor.

i bet lol but that CR is way to high for me... machine shop told me 9.7:1 with a 60cc...
i dont know anything yet on them... i will find out the info on them for you...get a part number and a specs sheet

dc

great to know man thanks...yea i hadnt picked a cam out yet... i converted to mass air so i have some options over the SD junk...
thanks

When I made that last post I forgot you were running a roller block, lol. In any case, I still highly reccomend the extreme 4x4 cam profiles. Talk to Comp, I'm sure they could grind you a roller cam with similar specs if you want to go that route.

yea ive been cam shopping lately...not finding too many options at summit for low RPM power

yea ive been cam shopping lately...not finding too many options at summit for low RPM power

have you talked to fireguy? he seems to really know cam stuff. Might be able to at least point you in the right direction.

yea ive been cam shopping lately...not finding too many options at summit for low RPM power

Yup, but as I'm sure you're well aware of, with the increased displacement of your storker motor you will need a slightly bigger cam to do the same thing as a 351" motor. IE, you can handle more lift and duration and still make good low end (to a point).

Yup, but as I'm sure you're well aware of, with the increased displacement of your storker motor you will need a slightly bigger cam to do the same thing as a 351" motor. IE, you can handle more lift and duration and still make good low end (to a point).

dont say that too quickly... im not well versed in cam specs and selection... im a little lost actually


dc

dont say that too quickly... im not well versed in cam specs and selection... im a little lost actually


dc




I was confused too..... call somebody that can grind a cam for YOUR motor.


I went with these guys.

http://www.schneidercams.com/

just talked to the guys at the machine shop... they can get me a custom grind done for about $250...

i may wait on the custom grind though and go with a crane cam(444211) for now... when i get the heads i want down the road ill have a custom grind cam made

dc

I would get the heads and intake figured out first. Then I would hit up a few of the major cam companies and get there opinions. I was eyeing the extreme4x4 cams.

ok so lately its been a little crazy with school and stuff.. so i havent gotten much progress done... plus i need to finsih up the rear frame rails and i need at least one other person to help me... i havent had that person around lately...

anyways... did get a little work done over the weekend... filled all the holes not being used a flap wheeled them down(60grit) flush... still have a few more to do but the majority of the work is done... need to cut out some plate for the big holes... i tried backing the hole with a piece of copper, but it is really a lot easier just to free hand the fill.. and was coming out cleaner
d-side mostly done and smoothed
http://www.supermotors.net/getfile/624015/fullsize/dissasembly-001.jpg
pass side before the flap wheel...
http://www.supermotors.net/getfile/624017/fullsize/dissasembly-002.jpg

so today: managed to limp the bronco up the street and into the shop... yea with no oil pressure lol... the last time we will see it like this: sigh.... and i just built this a year ago
http://www.supermotors.net/getfile/624019/fullsize/dissasembly-003.jpg
http://www.supermotors.net/getfile/624020/fullsize/dissasembly-004.jpg
this pic makes me dizzy... anyways... started tearing into it... down to the core support up front

http://www.supermotors.net/getfile/624021/fullsize/dissasembly-005.jpg
main harness out
http://www.supermotors.net/getfile/624022/fullsize/dissasembly-006.jpg
d-side fender gone
http://www.supermotors.net/getfile/624023/fullsize/dissasembly-007.jpg
front end cleared... getting ready to pull the bumper
http://www.supermotors.net/getfile/624025/fullsize/dissasembly-009.jpg
one of the body mounts from in the cab... we warned those of you who like mudding and what not... this truck has been mudding 5-6 times maybe... and every body mount hole looked like this... rusty and full of dirt...
i managed to get all of the body mounts undone by myself...
http://www.supermotors.net/getfile/624026/fullsize/dissasembly-010.jpg
superflex dana 44 cage arms... prolly the cleanest/clearest pic of the SAS geometry...
http://www.supermotors.net/getfile/624027/fullsize/dissasembly-011.jpg
random shot from the side
http://www.supermotors.net/getfile/624029/fullsize/dissasembly-013.jpg
trying to get it squared up to the lift... it was awkward finding a good spot to get the body off with the lift...
http://www.supermotors.net/getfile/624028/fullsize/dissasembly-012.jpg
dropped it onto some rolly carts

http://www.supermotors.net/getfile/624030/fullsize/dissasembly-014.jpg
WHOOOOO!!!!!:chili:
http://www.supermotors.net/getfile/624031/fullsize/dissasembly-015.jpg
http://www.supermotors.net/getfile/624032/fullsize/dissasembly-016.jpg
http://www.supermotors.net/getfile/624034/fullsize/dissasembly-018.jpg
http://www.supermotors.net/getfile/624035/fullsize/dissasembly-019.jpg


once again... by myself... the whole time... im whooped and im going to bed.
next ill get the drivetrain mocked into the new frame... then make some motor mounts

dc

Keep up the good work DC. I've been watching on FSB.

Cool build man. Keep it going.

a little update:

body went down to my house on a very small trailer lol...only a 1/4 mile away
http://www.supermotors.net/getfile/625398/fullsize/frame-019.jpg
got the rear frame rails finished...they still need guesseted
http://www.supermotors.net/getfile/625396/fullsize/frame-017.jpg
http://www.supermotors.net/getfile/625397/fullsize/frame-018.jpg
stock drivetrain in for mockup... needed to get an idea of the angle before i threw the 4r70w on
http://www.supermotors.net/getfile/625399/fullsize/frame-021.jpg
threw together some pieces of metal to keep everything in place so i can make the new motor mounts
got the motor even between the mounts
http://www.supermotors.net/getfile/625401/fullsize/frame-023.jpg
driveline angle
http://www.supermotors.net/getfile/625402/fullsize/frame-024.jpg

nothing to big lately... been kinda hectic...

decided tonight i would re-use the factory fuel tank... its gonna get turned 90* in the frame rails and i will cap and re-weld a new filler spot...

dc

Lookin good. keep up the work.

oh and i didnt mention... last night i got a FREE dana 60 kingpin :D

I know you are gonna share the love man... My buddy just got one outta pic-n-pull.....225 dollars.... WTF, where are the rest of us at??

yea i know dude... i got super lucky...

its an 89 f350... i paid $250 for the whole truck(which is worth that in scrap metal so its practically free)... it had the kingpin 60 front...10.25 rear sterling.. a plow hydro pump and a running 460 EFI

i made out pretty good lol

im going away tommorow... no updates for at least a week or so

have you talked to fireguy? he seems to really know cam stuff. Might be able to at least point you in the right direction.

http://www.fullsizebronco.com/forum/showthread.php?t=6867


DC just incase you did not see fireguys thread on choosing efi cams.

okay so heres a little update:

built some 3" wide poly motor mounts... used the origional backing plate from an off the shelf set of bushings
http://www.supermotors.net/getfile/638449/fullsize/xmembermotor-001.jpg
cut the xmember out...
http://www.supermotors.net/getfile/638451/fullsize/xmembermotor-003.jpg

the new xmember is almost finished... i spent a rediculous amout of time building tabs for it tonight but they came out great... it unbolts for oil pan service... engine xmember bolts up using 4 gr8 3/4" bolts... pics of the xmember and stuff tommorow


motor update...
393w... all the parts are in mostly...
eagle cast crank
5140 I beam rods
pistons(stock stang piston with 12cc dish) - $8 each :D
felpro gaskets
Dart 170cc aluminum heads
Professional products manifolds all smoothed out and gasket matched
custom grind cam
bla bla bla

final CR is 10.5:1

this thing is gonna run its a$$ off... 4r70w is being built now

dc

Sweet Build, keep us posted.

soem random pics for tonight... the xmember is 50% done... unbolts... 4 - 3/4" bolts do that job... its WAY overkill, but the store i was out of 9/16 and these were just sitting on the bench needing a use... it was like 10PM last night when i was drilling these
anyways...
http://www.supermotors.net/getfile/640515/fullsize/xmembermotor1-001.jpg
motor mounts obviously still need gussetted
http://www.supermotors.net/getfile/640517/fullsize/xmembermotor1-002.jpg
http://www.supermotors.net/getfile/640521/fullsize/xmembermotor1-005.jpg

need to finish the xmember and plate the joints... bla bla

prolly gonna go back up to the shop and mess with the welder... its being poopy

dc