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Old 08-06-2011, 11:51 AM   #1 (permalink)
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69 bronco crawler build

Started a major rebuild on my 69 bronco about 20 months ago. Finally got it out on the trail this June.
Figured Id post some pic's of the build & what it looks like now.
Here is the specs before & after.

Before;




5.89 gears
D44 front/30spl cro mo shafts & u-joints/Detroit Locker
9inch rear 31 spl alloy shafts/Spool
39.5 IROKS
5.0L efi
stock 3 spd manual
D20 t-case
Full Hydro steering
streached 13" rear/4" front
4 link rear w/t coilovers
radius arms/coils front

After;




5.38 gears
D60 front/35 spl cro mo shafts inners & outers/cro mo u joints/ARB Locker
D60 rear 35 spl alloy shafts/ARB Locker
42" SUPER SWAMPERS
5.0L efi
C-6 trans
205 t-case/NW Fab cable shift twin stick
Full Hydro steering
4 link rear w/t coilovers
3 link front w/t coilovers

started by gutting the interior & cutting out the floor to make room for the C6/205 setup;




Fabbed a cross-member & began mocking up the suspension;




installed NW fab cable shift kit for the 205 & began putting sheetmetal back on the floor;




Gor rid of the dash, moved the brake pedal assy left 2";




To make room for the brake booster without the giant offset bracket contraption;

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Last edited by bronco69drp; 08-06-2011 at 12:37 PM.
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Old 08-06-2011, 12:00 PM   #2 (permalink)
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fabbed the front shock hoops out of .120 wall 1.75'' d.o.m.



after many, many mock up's & trials, settled on a 3-link setup;



Front D60 hi-pinion(out of 93 f350)axle in place



Front discs;

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Old 08-06-2011, 12:16 PM   #3 (permalink)
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Began work on the rear D60. Out of an 99 E350 van.(This is the smooth bottom D60 with the heavy duty (d70 hubs & spindles-no boring required for 35 spline axles however the diff is offset 3'' to the passenger side) To use the Sniper Fab truss I wanted I had to shorten the drivers side tube 3''. So I cut off 3'' sleeved the tube & welded it back up.

Rear D60 with truss on.



Rear ARB install;



Axle in place & rear discs on;

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Old 08-06-2011, 12:32 PM   #4 (permalink)
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With the suspension done & axles in place I began working on the interior.

Closed up the hole in the floor & began the center console & dash mock up;



Then got it welded up & the tabs for the side panels welded on;



Then finally skinned it;

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Old 08-06-2011, 01:38 PM   #5 (permalink)
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Then went to work on the tube doors





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Old 08-06-2011, 01:56 PM   #6 (permalink)
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After all the months of fab work it was time for the details;

Wiring; Battery & main fuse panel;



Aux fuse panel & relay panel;



Instrument panel;




main battery disconnect;



Digital dash



Engine bay wiring:






Plumbing fuel filter & lo press pump;



Fuel cell;

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Old 08-06-2011, 02:04 PM   #7 (permalink)
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Nice looks like it would work nicely.
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Old 08-06-2011, 02:13 PM   #8 (permalink)
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Never much liked a traditional steering column in a crawler so I made my own;



Steering linkage in the eng bay;



Because of the broncos narrow frame & the C6 now installed I got creative & fabbed my own exhaust;

Drivers side;





Passenger side;



http://classicbroncos.com/photos/dat...exh_pass_2.JPG
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Old 08-06-2011, 02:24 PM   #9 (permalink)
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Finaly after all that time everything came out & the crawler got a freash coat of beadliner



Seats went back in;



The interior together.



Powered up;

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Old 08-06-2011, 02:49 PM   #10 (permalink)
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Finaly this June it was time for the firs trip out to Harlan KY

Loaded up;



At the trail head above Putney campground;



Lower rock garden;



Pics from camp;







The shakedown run went well I was really happy with the new suspension & C6 tranny. The rig crawled up everything I pointed it at.
Still have some tuning of the coilovers to do & small other details, but overall worth all my time & money invested.
Next trip; Bronco Roundup 2011 @ Hot Springs. Hell Yea
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Old 08-06-2011, 02:56 PM   #11 (permalink)
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any more pics of the front drivers side link mounts?
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Old 08-06-2011, 03:11 PM   #12 (permalink)
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Quote:
Originally Posted by plug ugly View Post
any more pics of the front drivers side link mounts?
I will take some pic's & post them in a couple days.
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Old 08-06-2011, 11:47 PM   #13 (permalink)
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What does the rig weigh? I'm guessing you own a tubing bender.
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Passionately centerist. We're slowly being killed by the far left and far right.
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Old 08-07-2011, 04:55 AM   #14 (permalink)
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Quote:
Originally Posted by NOTPRETTY View Post
What does the rig weigh? I'm guessing you own a tubing bender.
Haven't had a chance to weigh it yet. Yes a JD2 hyd bender.
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Old 08-07-2011, 06:17 AM   #15 (permalink)
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good lookin bronc
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Old 08-07-2011, 07:52 AM   #16 (permalink)
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Nice fab work. Diggin the console
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Old 08-07-2011, 07:55 AM   #17 (permalink)
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Here is a vid of a little climb on the Harlan KY trip;

‪video 2011 06 17 12 28 51‬‏ - YouTube
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Old 08-07-2011, 03:38 PM   #18 (permalink)
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Looks awesome! i really like the center console and interior!
Looks like you could use a doubler!
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Old 08-08-2011, 07:28 AM   #19 (permalink)
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Quote:
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Looks awesome! i really like the center console and interior!
Looks like you could use a doubler!
Thanks. I spent allot of time tiring to get the interior as comfortable for me as possible.
As far as a doubler goes, with the lower gears in the axles, I dont have too many issues crawling over obstacles. However I do have a heavy right foot
My plan is to buy an ATLAS T-case with maybe a 3:1 or 4:1 once I get some more time testing/tuning the rig & see what I think would be the best ratio(and of course when the wife allows the funds for more bronco stuff)

Here is another feature in the center console, a compartment for misc crap;

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Old 08-08-2011, 09:37 AM   #20 (permalink)
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looks good i bet that thing can roll pretty good, i like all the custom body work looks like my custom body work on my piece. !!!
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Old 08-08-2011, 09:48 AM   #21 (permalink)
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Quote:
Originally Posted by plug ugly View Post
any more pics of the front drivers side link mounts?
Here is some pic's of the front driver side links;

lwr link frame mount;



frame link mounts;



lower link @ frame;



upper link @ axle;

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Old 08-08-2011, 10:52 AM   #22 (permalink)
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that's a bad piece you have there. I cant wait to start building a 66-77 EB.
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Old 08-08-2011, 05:01 PM   #23 (permalink)
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thanks. any of the backside of the axle? What did you weld it with?
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Old 08-08-2011, 08:39 PM   #24 (permalink)
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cool rig, i wondered where this things been hidin lol
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Old 08-09-2011, 05:14 AM   #25 (permalink)
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Quote:
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thanks. any of the backside of the axle? What did you weld it with?
I will try & post some pic's.
All the welding was done with a Lincoln mig using flux core wire. The thick stuff I preheated the area with a torch & made more than 1 pass.
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