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Bronco Blitz. Desert Thrashers 1 ton build up thread.

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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
Here's the radius arms all tacked together. After cycling the suspension I determined that I can use 14" coilovers. Now I need to figure out what spring rates to get. Anyone have suggestions?
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
I went ahead and removed the big tall brackets from the old van conversion. I determined that I could not fit a long enough coilover with them, so after some plasma cutting and lots of grinding, out they came.
Next I got the all the steering built, just need to fully weld it up. Also got the trackbar all tacked together. It came out great, perfectly parallel with the drag link. Tomorrow I will articulate the axle and check clearances. Once that's done I can fully weld up everything. I'm only missing the coilover tabs for the axle, which are coming from Ballistic Fab so we'll see how long that takes.
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
I decided to rework the trackbar by making it longer. I cut out the back of the upper arm mount and fit the trackbar bracket in it. It's about 6" longer and much better now. Before it would hit the diff at full bump, now it clears easily and it stays parallel to the drag link when articulated. After testing I liked how it was so I went ahead and welded it up, I just need to add some gussets, then it will be done. I also had to cut the bottom of the engine crossmember off to clear the drag link when articulated. I need to re-plate it still. uploadfromtaptalk1431663829647.jpg
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
Now for some bling. I got a great deal on Fox 2.0 coilovers from Daves offroad supply. Got viper coils for them. Also got the mounting tabs from Ballistic, I need to modify them a little. They are for a king pin axle and mine is a ball joint, just a little grinding should be enough to make them fit. And I found some nice wheels for a good price. They are Hummer H2 wheels, and I think they will look great. At least until I can afford beadlocks later on. The center bore is too small to fit over the large sterling hub and the D60 also. So I took them to work and put them in a mill and cut the centers open to fit. They fit great now.
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
Thanks! I am, but it feels like I am way behind. I had a wheeling trip planned for end of this month, but I won't have the Bronco done by then, so I will be a passenger. Anyway I hope to have it sitting on the coilovers this weekend. Then I can start the rear build.
 
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Desert Thrasher

Desert Thrasher

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Jul 14, 2001
Messages
2,353
Well I actually achieved my goal of getting the Bronco sitting on her suspension this weekend. Saturday I spent the whole day finishing up things. I added gussets to the trackbar/upper arm bracket, added some cool gussets to the towers, modified and welded on the lower shock tabs. Then I reinforced the engine crossmember by using some 1x2 rectangle tubing with a piece of 3/16" flat bar to make it 1x2 3/16" to fit snuggly inside the old crossmember and welded it up. Also installed the springs on the Fox coilovers. Then today I cleaned up the axle some and the frame. Then painted it all with Rustoleum hammered black with primer. After it dried I installed the coilovers and set her on the suspension for the first time since February. Coilovers are a PITA to install!
The little spacers to line up with the heim ends are a major pain to install. She sits about 1.5 to 2 inches higher than I planned, so I will have to see what I can do to adjust that. I'm happy with it though, I think it looks great! So excited to see it on its own suspension again!
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Desert Thrasher

Desert Thrasher

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Joined
Jul 14, 2001
Messages
2,353
I decided to change the frame brackets for the radius arms. The brackets I had are in line with the frame which puts the johnny joints at almost max angle just sitting there. So I bought some trick brackets from Artec that are tear drop shaped so I can angle them on the frame. They worked out perfect! Lined up perfect with my arms. Also got the steering all bolted up. uploadfromtaptalk1432435153034.jpg
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
I mounted the reservoirs, using Ruff Stuff mounts. I put them on the front of the towers to keep them away from the headers.

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gunnibronco

Sr. Member
Joined
Apr 13, 2008
Messages
496
Loc.
Gardnerville, NV
What year D60 are you running?

I have a 95 ball joint D60 I want to use in the future, and am looking for 17" rims. I read H2 rims are 5-1/2" or 5-5/8" backspacing. I wasn't sure they would clear the tie rod ends. It looks close with some rough measurements.

Thanks
Chad
 
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
I have a 97 D60. Yea the H2 rims are 5 5/8" backspacing. I have not fit them on yet so I am hoping they clear the tie rod.
 

Yeller

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Mar 27, 2012
Messages
5,881
Loc.
Rogers County Oklahoma
The H2 rims will clear the tie rod. Just be sure to open the center hole .200" other wise they do not clear the hub pilot. I've had them machined but with a little time, a die grinder with a carbide bur and a lot of WD-40 will do the trick. The WD-40 lubricates the bur and keeps the aluminum from plugging it up.
 

gunnibronco

Sr. Member
Joined
Apr 13, 2008
Messages
496
Loc.
Gardnerville, NV
The H2 rims will clear the tie rod. Just be sure to open the center hole .200" other wise they do not clear the hub pilot. I've had them machined but with a little time, a die grinder with a carbide bur and a lot of WD-40 will do the trick. The WD-40 lubricates the bur and keeps the aluminum from plugging it up.

Thanks for the info.
 
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
Haven't got much done lately. Just too much other stuff getting in the way of my Bronco wrenching time. Anyway I got the new 35 spline chromo stub shafts and Spicer Ujoints together. I had to grind/radius the edges to fit through the pilot hole in the knuckle, nothing a flap disc couldn't handle.
Next I cleaned all the old grease out of the hubs and replaced the bearings and packed it full of new grease.
Then I was able to install the Yukon hardcore lockouts. They look great, a little tight to turn the knobs though, I hope they work themselves in and loosen up some eventually.
Also started getting the brake parts together. I painted the caliper brackets and calipers. I need the bolts that hold the caliper bracket to the knuckles, does anyone know what thread it is? I'm thinking it might be metric, because a 5/8" starts but won't thread in. So maybe a 16mm?
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Apogee

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Nov 26, 2005
Messages
6,033
Looking good. M16x2 threads on the pad abutment brackets for those calipers IIRC.
 
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