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Old 06-15-2012, 06:10 PM   #1 (permalink)
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Hellwig 68 Bronco Project

Hi everyone, this is the build up thread for the Hellwig Products 1968 Bronco project. We tore it apart today so it's time for a build up thread. We basically have a Bronco that we're just keeping the body and VIN and everything else will be new.

Plans:
2011 Ford Coyote 5.0 crate engine
6R80 Tranny (6 speed auto w/ 4.17 first gear)
3:1 Atlas T-Case
Art Morrison Frame
Delphi steering box w/ ram assist
Fox Coilovers
Hellwig Sway Bars (obviously)
Currie High Pinion 9 Inch Axles (most likely 60 outers)
And a million other details

We've started ordering everything this week so all the plans are coming together. We'll see how the plans change/evolve over the next couple weeks. Our plans is to have the suspension on the frame with the drivetrain mounted by SEMA to have in our booth. Then get back, finish everything else including body and then take it to Moab!

Now, pics:


How it showed up, plates with Feb 1988 stickers...


Playing a little before teardown and to check clearance on our Bronco sway bars. LOTS of frame flex put the fan into the radiator...


Interior


Original 289 with X23,000 miles. Your guess on the first digit...
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Old 06-15-2012, 06:20 PM   #2 (permalink)
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Today we tore it all down! There was just as much grinding as there was use of sockets to get everything apart. There's some solid rust repair/bodywork in the future... Overall though, everything went pretty smooth.


Does this topless pic count as 35%?


Stripped


Our synchronized fork lift body removal dance. Worked really well and let us leave all the drivetrain intact


Body


Everything else
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Old 06-15-2012, 06:22 PM   #3 (permalink)
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And the first of many new parts are here! Maybe no more backfiring with this one like the 289 it used to have?


Ford 5.0 Coyote still in the crate. Opening that container was a great feeling!
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Old 06-15-2012, 06:31 PM   #4 (permalink)
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Don't you dare cut the body up on that.
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Old 06-15-2012, 06:36 PM   #5 (permalink)
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Quote:
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Don't you dare cut the body up on that.
Heads will roll
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Well..... It sounded like a good idea at the time.
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Old 06-15-2012, 06:43 PM   #6 (permalink)
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Quote:
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Don't you dare cut the body up on that.
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Old 06-15-2012, 06:46 PM   #7 (permalink)
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I don't think his plan is to cut it though so

That's way too nice to chop up.
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Old 06-18-2012, 07:36 AM   #8 (permalink)
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Don't worry, 42s and comp cut fenders are not in this rig's future. The most we may have to do is a little inner fender massaging for the Coyote motor and the rear fenders have already been trimmed a bit when we bought it.
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Old 06-18-2012, 08:00 AM   #9 (permalink)
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That Coyote 5.0 is tits. What tires are y'all planning for it?
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Old 06-18-2012, 08:20 AM   #10 (permalink)
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Quote:
Originally Posted by Dr.Danger View Post
That Coyote 5.0 is tits. What tires are y'all planning for it?
It definitely is a sweet engine. I keep saying if they decide to go with something different I think it would have a good home in my Ranger! (wishful thinking)

We're not sure yet on tires, we have some different almost new and new sets of tires (35s and 37s) floating around the shop from previous projects and we're going to get the suspension done and see what works best... Most likely going to be one of the sets of 35s though.
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Old 07-19-2012, 08:23 AM   #11 (permalink)
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Parts have started trickling in. As usual Randy's Ring and Pinion had us covered and got us our stuff right away.

We got the Randy Nodular Daytona 9" third member for the rear with 4.86 gears and a Grizzly locker. The Daytona has a nice big pinion support that we really like.



We also got some Randy D60 35 spline flanges (YHC 50005) and D60 35 spline Yukon spin free locking hubs (YHC 70002). The locking hubs look really beefy and have that added bling factor.





We got our 6r80 transmission out of a wrecked 2011 F150 5.0 with only ~1000 miles. The tranny's bolted to our Atlas t-case adapter made by Tumblin Automotive. The adapter is really nice and uses all the factory seals and bolts right up!



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Old 08-06-2012, 03:17 PM   #12 (permalink)
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We're getting anxious and want to get going on this (SEMA is just around the corner) but while we wait for more parts we installed our bling, heat treated locking hubs from Randy's on our axles. Progress!

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Old 08-06-2012, 03:25 PM   #13 (permalink)
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Old 08-09-2012, 07:04 PM   #14 (permalink)
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The first thing I thought when I saw your first pic was...oh please don't cut that body up!

I really want to run the 5.0 also..how much did it set you back?

I'll be watching this build!
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Old 08-11-2012, 09:16 AM   #15 (permalink)
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I was wondering how long before someone built an eb with a Coyote. Fucking sweetness is all I have to say.
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Old 08-11-2012, 11:24 AM   #16 (permalink)
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It's been done....

http://classicbroncos.com/forums/sho...ghlight=coyote

http://classicbroncos.com/forums/sho...ghlight=coyote

http://classicbroncos.com/forums/sho...te#post2134486
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Old 08-14-2012, 08:26 AM   #17 (permalink)
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It's been done....
Yeah, some guys have done it but it's not like it's a set swap. We think being in the first few to do it is still pretty solid and believe us, there's no map and lots of figuring out to do.

This last weekend I went to Sierra Trek on Fordyce Trail instead of working on the Bronco. It's beautiful up there and in my opinion harder than Rubicon. They had a DJ and a full bar and a pretty legit raffle. All the proceeds go to Cal4Wheel Drive so a good cause.

I did the river run where we went from the end of the trail backwards through the last 3 winch hills, crossed the river and then came back. One guy blew up the bearings in his D60 and there were three broken TJs (driveshaft, tie rod, drag link) but I rode with the VP of Cal4 in his YJ and we didn't have a problem. My highlight was watching Big Mike from Marlin Crawler put his Toyota in triple low (511:1) and get out of the vehicle and let it go up Winch Hill 5 without him in it.

Full Album of Pics Here

Meadow Lake where we camped (end of the trail) and our F250


Flexed out ice cream truck


Sweet backhalfed, exoed Dodge
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Old 08-14-2012, 10:05 PM   #18 (permalink)
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I wasn't knocking you or your attempt, just showing the previous poster there are a couple of them in the works. I don't envy you as far as the research needed to figure it all out.
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Old 08-15-2012, 07:54 PM   #19 (permalink)
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Thanks for the links, its one of those things I love to see but dont have the funds to think about doing. Im glad to see theres a modern Ford motor that is getting a following maybe before long we wont have to see bastardized Ebs with ls engines.
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Old 08-20-2012, 05:45 PM   #20 (permalink)
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Well, took some pictures of our axles and progress there. Currie Enterprises made us some awesome stuff!

Currie front axle housing with 3.25"x3/8" wall tubing and 1 ton knuckes


Currie rear axle housing with 3.5"x3/8" wall tubes and 1 ton outers


Our front Currie third member with 4.86 gears and ARB locker
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Old 08-20-2012, 06:15 PM   #21 (permalink)
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Our original plan was to set up the suspension the old fashioned way with the frame, finding center line, designing brackets, etc but while we wait for the frame it seems like SEMA is just around the corner so we decided to try something new for us to speed up the process. We measured our axles with our CMM and then using data from that and both Currie and Art Morrison we designed our brackets, are having them laser cut and will get them tacked into place before we even have the frame in hand. We'll see how it works out!

Measuring the rear axle with our Faro arm


Rear axle measured with the Faro arm


Rear axle with bracketry for the sway bar, coil overs and four link


Front axle measured with the Faro arm


Front axle with bracketry for the coil overs and radius arms
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Old 08-20-2012, 06:33 PM   #22 (permalink)
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Old 09-06-2012, 04:05 PM   #23 (permalink)
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We got our frame in from Art Morrison. It came with most of our bracketry already welded in place and is really a piece of art.

Taking it our of the crate


All ready for suspension and drivetrain


Skid plate


Rear coilover mounts


Front coilover mounts


Stack-o-dimes on the link brackets


We also have our front radius arms and rear links for our 4 link with some huge Johnny Joints

Front radius arms


Rear 4 link


Begin overtime run to make SEMA!
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Old 09-06-2012, 07:36 PM   #24 (permalink)
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Surprised you didn't go with the tube frame being produced by one of your vendors, Krawlers Edge. I think they offer endless custom bracketry. That on's hella nice too though.







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Old 09-07-2012, 08:00 AM   #25 (permalink)
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Surprised you didn't go with the tube frame being produced by one of your vendors, Krawlers Edge. I think they offer endless custom bracketry. That on's hella nice too though.
We have a good relationship with both Krawler's Edge and Art Morrison. Both are badass frames with a lot of engine mount and suspension options. We think you can't go wrong either way!
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