The Ultimate Bronco

[dieselbronco]

This is going to be my first build thread so bear with me.

about three years ago i put a 4BT cummins 3.9 into my rusted out 1969 bronco. its running an NV4500 and a dana20. It was the best thing I've ever done. Sorry i don't have a ton of pics for that swap right now. i have to find them and try to get them on the computer. the next part of the build is going to be the axles. I've been debating on what to do with them. Do i bullet proof them with lots of money or swap in some 60's. well here is some pics of what i have started

 

[dieselbronco]

heres a couple of pics i took last month when i redid the front clip and installed the intercooler.

 

[dieselbronco]

I've started building the front and rear shock hoops, and some killer spring pads

 

[dieselbronco]

sorry i don't know why the pics are crooked?

 

[monkeylovetrees]

Looking good sence I was last there keep up the work

 

[dieselbronco]

i've started the narrowing process. first i cut the old c's off a junk front axle. then i welded them together the same distance apart as if they were still installed. next i chucked them up in the drill press and cut them to fit the dana 60 axle tube. after some clean up and some narrowing i moved to the axle.

 

[dieselbronco]

since the axle is from a newer truck i had little room to fit the c's. (but more room to clear the oil pan) i had to trim the spring pad area of the housing. i took as little off as i could witch ended up being around 3/4 of an inch. they just fit now.

 

[dieselbronco]

next it was time to narrow the tube. I'm looking to get the final width around 64 inches, so i lopped the knuckle off and cleaned up the tube. after cutting into the weld i was able to push out the slug and clean it up. i set the knuckle on the grill and warmed it up so i could slip it on and set the caster to match the driver side. tomorrow i will weld it up and start pulling the old 44 out to mock up the 60.

 

[DonaldDouchebag]

I've started building the front and rear shock hoops, and some killer spring pads

Are those motorcycle handlebars in the fourth photo?

 

[dieselbronco]

sorry to jump around but i found a couple more pics of the turbo install.

i took an hy35 and made my own exhaust housing end plate, with a blow off eliminator. then i took the two roll pins out that hold the housings from spinning so i could clock it where i needed it to be. there is also a pic of the intercooler from a first gen dodge that i used. i had to take a couple inches off the bottom to clear the steering box.

 

[Devin]

Holy fab work, batman! That is awesome. Nice shop, too. Wish I had one like that.

Keep the pics coming....

 

[dieselbronco]

I've got some more pics of the past weekends progress. the 60 is in and fits better than i could have dreamed!i welded up the knuckle then set the caster by first take measurements off the dana 44. i installed stock radius arms on the 44 with the ball joints set level. then i checked the degree that the arms were with a friends digital level. after i had all the measurements i installed the arms the same way on the 60 and matched every thing up. then welded her solid and slapped some paint on it

 

[sprdv1]

Nice work!! Went with the 60s I see

 

[AnthonyJ124]

I registered to verify how LEGIT this build is. The swap and fab work are great. Great guy too!

Thanks for the wheels!

-A

 

[blazinchuck]

nice build...lots of work!!!

 

[dieselbronco]

Thanks. I hope to have it done before BYOB.

Progress has slowed some but i did get the front shock hoops mocked up. Just need to decide if i like them, then weld them solid.

 

[motoman]

Love the build! ;D Love turbos! ;D

 

[dieselbronco]

a couple more pics of the rear end all painted up with the spring pads, shock mounts, and brake brackets welded on.

 

[dieselbronco]

I've moved back to the front this weekend. removed the factory trace bar mount and fabed up a new one. i had to move the mount 2" down and 2" out due to the higher position of the tie rod on the new axle. plus i wanted to beef it up a bit. i'm using 7/8 rod ends and 1 1/2 x 1/4 wall dom for the trace bar.

 

[dieselbronco]

here is the axle side of the mount, and my new toy.