My '93 Bronco Build

[BadAssEddie]

So, I reckon I have gotten far enough into this build to warrant starting a build thread.

I've been interested in automotive pursuits and wheeling since I was about 14, but I have never delved into something this in depth before and am pretty excited about finally doing a build I've been yearning to start for some time.

I am a sophomore at Virginia Tech and I am working an engineering Co-Op for the Spring and Summer, so now I actually have the income as well.

I have a 1993 Bronco, and my general plans for it are as follows:

• 3 link front and 4 link rear
• Dana 60 front and Sterling 10.25 rear (keeping the stock 4.10 for now, planning on regearing shortly after the build is complete and I shake down the rest of the rig)
• FOA 2.0 14in travel reservoir coilovers all the way around
• Full hydro steering
• Playing with boatsiding
• Running 38 Swamper SX's on H1 beadlocks and runflats
• Roll cage
• Rebuilding my E4OD and BW1356
• Would like to do some engine work, but that is last on the list and will be subjected to how depleted my finances are
• Fuel Cell

[BadAssEddie]

A few pictures of my shop where the Bronco is:






I had to piggyback this air tank onto my compressor because my sandblaster was killing it way too fast. It helped a little.


This is a picture of my Bronco last year at Crozet. 33" AT's and 4" Superlift, stock otherwise.

[BadAssEddie]

I have ordered a whole bunch of parts and pretty much the only large purchase that I have left are my double ended ram and a set of headers. I have pictures of some of them:




I also have rear disc brake components (running Ruffstuff brackets with Chevy calipers, pads, and rotors), alot of misc tabs, all my link tabs and brackets, Ballistic diff covers, Ballistic High Steer arms, steering heims, and my DOM and plate order. I am running 1.75x.120 wall uppers, 2x.5 threaded lowers with JJ's on all sides. My panhard will be using heims on both ends, however.



I welded up my rear carrier and axle tubes front and rear. I kept the front open as I want to keep some form of agility with having a fullsize rig and longer wheelbase. If I find that I want more traction I will weld the front as well.




The tons sandblasted, primed, and setup under the truck where I want them. 19" off the ground (my 38's measure like 35.75" ), 7" of uptravel, 110" wheelbase, and pinion angles setup.

I guess that is all I have so far...

I think I am going to Herculine the interior of the Bronco and wrench on my DD this week/end, but will be updating as I make more progress.

Thanks for checking it out guys

[150]

build is looking very sweet so far! i wish i had a shop like yours..
and i vote you boatside it so i can decide wether or not i wanna do mine

[zdaily]

Nice build! Mine is mini boatsided, which I really like because the doors are still functional and not too extreme. I'll be watching this, good luck!

[BadAssEddie]

Originally Posted by 150

build is looking very sweet so far! i wish i had a shop like yours..
and i vote you boatside it so i can decide wether or not i wanna do mine

Hahah so when I fuck mine up, you'll know not to do it.

Originally Posted by zdaily

Nice build! Mine is mini boatsided, which I really like because the doors are still functional and not too extreme. I'll be watching this, good luck!

Hmm, Interesting. Would this be in a build thread of yours? I'd like to check it out.

[150]

Hahah so when I fuck mine up, you'll know not to do it.



haha well ya pretty much but also see how hard they would be with cuttin up all the body.. how high up would you make them? I was thinkin of puttin mine at the lower body line

[BadAssEddie]

Originally Posted by 150

Hahah so when I fuck mine up, you'll know not to do it.



haha well ya pretty much but also see how hard they would be with cuttin up all the body.. how high up would you make them? I was thinkin of puttin mine at the lower body line

I'm thinking of taking it up to the top of the frame rail. I would then be able to run sliders straight off the frame.

[triplesix]

Mine is cut 1" above the body line/crease.

Go for it!

[150]

so have you got anymore work done on it?

[freerider5.0]

Originally Posted by triplesix

Mine is cut 1" above the body line/crease.

Go for it!

You got a build link on yours?

[norfolkff05]

sweet build underway, i'll definitely be following. i envy your work area...nice shop! check out fsb.com, if you haven't already. there is a section for the local chapter there to keep up on any trail rides or other get togethers. there are a few of us in tidewater, va and some in your area/nova too

[BadAssEddie]

Originally Posted by norfolkff05

sweet build underway, i'll definitely be following. i envy your work area...nice shop! check out fsb.com, if you haven't already. there is a section for the local chapter there to keep up on any trail rides or other get togethers. there are a few of us in tidewater, va and some in your area/nova too

Yeah I've been a member over there since 07 or 08. I have been meaning to post the thread over there as well, but have just been super busy recently. I'm going to try to get over to the shop this weekend and turn some wrenches. Might have some updates first of the week.

[Runs You Over]

Cant wait to see how she turns out

[BadAssEddie]

In order to keep the Pirate masses happy and prevent my build thread from dieing, I am providing an update with no pictures

I finally received my Hi-Steer arms from Ballistic. Dave is a really nice guy and very professional but they need some help over there. Too much sun bathing and flat brims can wreck customer service .

So, as of now, the only major purchase I have left is my hydraulic steering system. I was trying to go the cheaper route, but due to time constraints, sloth, and impatience I feel that I will be buying a PSC kit soon.

I broke my finger last week so I'm not sure how much I will be able to get done this weekend, but the plan is to wrench. I want to get my rear truss bent with the newly installed Pro-Tools bender along with my coilover towers. I was playing with the idea of making an engine cage to tie the front ones into, but I do not believe I have enough tube for such a thing.

I will be pulling the transfer case and transmission next week as well. When the BKO was still on the road, the check engine light would come on once the engine was hot. The TC wouldn't lock up when the light was lit and would run rough. My gut feeling is that the transmission is failing as I abused it mercilessly my freshman year and I also feel that the O2 sensors are bad, keeping the ECU in an open loop, also preventing TC lockup (I think that's right ). However, I will not rely solely on speculation. Luckily, EEC IV codes can be pulled with a standard voltmeter and I have an old school Napa Diagnostics VHS to reference.

I will be trying to pull the rest of the odds and ends out of the cab and get my Herculiner applied ASAP.

Everything else is too far in the future to be any more than speculation.

I should be over there tomorrow so I will take some pictures of a few of my new goodies and the little bit of progress I have made since the last update. As I know all you illiterate fawks need visual stimulation to pique your interest...

Thanks for looking.

[BadAssEddie]

I forgot one thing...

The machine shop manager at work was nice enough to allow me access to the shop after hours (WTF was he thinking ???). Tomorrow morning I will be running up to Roanoke to pick up a 1.25-12 LH tap from my Uncle who owns a machine shop (the AMT shop at work has a RH one). And, over the course of the next few weeks I plan on machining my lowers myself as time allows, when I finish work for the day. I practiced with a few smaller scale pieces this week and conferenced with a couple of the machinists to get their advice. I am a bit nervous because 2"x.5" wall tube is expensive and i only have 12', but I feel confident that it will go well.

Thanks again,
Alec

[BadAssEddie]

I removed my hood to have more room to work with. I began clearing out the engine bay of the things i do not want like emissions equipment and so forth.




I cut my links to length and got my LH thread tap. I'm going to try my hand at machining them on Saturday.



I installed my bender and bent up this:



But, not before I broke it making my first bend. It is rated up to 2"x.134 wall which has almost the same area moment of inertia as 1.75x.25 (which is what I was bending ). So, I welded it back togther:



Then I added 5HP:



I will be over there alot this week hopefully. So, I'll make an update next weekend.

[BadAssEddie]

Been working on placing my drivetrain where I want it. Got my motor mounts and transfer case/transmission mount mocked up. A few pictures:


Got some headers for a damn good price.




Lowers are all done.

Hitting up the shop tomorrow.

[93ranger4x4]

good work. im interested to see how you mount your driverside links.

[yoder man]

These look a lot like mine in the sense they r 2" x .5" links and I did mine on a lathe also. I'm doing an EB with 4 link f/r. Nice build and keep ur fingers clear so we can see more progress. Thanks for your time.

[BadAssEddie]

Damn, school and work have been taking up alot of time. Only been over to the shop 3 times since the semester started, but I'm SLOWLY making progress.

Drivetrain is finished and in its final place. Took a couple pictures of what it looks like as of last night:



Flatbelly. The transmission is going to be in my lap though lol.


Transmission/transfer case crossmember.


Gained alot more clearance to stuff my suspension in. Still planning this out.



Headers installed.


Made new motor mounts.


These koozies are awesome too. My new favorite "tool" haha

[150]

so about how much did you move your whole drivetrain up?

[FordX4-offroad]

dude! this is awesome! a little more funded than what i am for now. but im in. and i totally agree with the school thing.. it kinda sucks

[BadAssEddie]

Originally Posted by 150

so about how much did you move your whole drivetrain up?

Id say close to 6 inches up and 4 inches back.

[Ford rules]

Awesome build! keep us updated.