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Bronco Blitz. Desert Thrashers 1 ton build up thread.

68rockcrawler

Bronco Guru
Joined
Sep 18, 2006
Messages
1,417
I moved my front axle forward 8" and went with the 4x4 box with forward facing pitman arm. My coil bucket is at the back of the steering box.

Post pics! I wanted to do that when I pushed my axle forward, but it didn't seem like it would work. From my recollection I think it looked like there would be interference between the tierods and drag link.
 
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Desert Thrasher

Desert Thrasher

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Joined
Jul 14, 2001
Messages
2,353
Made some progress today. I modified the body mount and core support to move the steering box forward. It looks like it will be 3.5" forward. Which is close enough to the 4" I was looking for. I had to cut into the lower lip of the grill but that's it.
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slowRoaner

Jr. Member
Joined
Jul 9, 2013
Messages
100
Loc.
Durango
Patrickk1- How is your steering column joint angle? Do your joints cycle? this is the only disadvantage i can see from pushing the box back.

Thrasher- looks good man, i see that you ended up cutting into the grill a bit, but unnoticable from standing position.

I just mounted up my 4x4x2 box in the factory location today. Im looking into which way i want to go as well, for when i stretch it someday.

one thing i did notice though, is that the pitman arm that was on my manual steering box, is shorter than the 4x4 box pitman, and the pitman off of the donor 4x2 ranger box is even smaller yet! So maybe if using the manual steering arm, one could get away with mounting it a little further forward, when in the 4x4 factory orientation......
 
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
I'm using a stock Bronco pitman arm, different lengths could be useful. Here is how I braced the body mount and core support as well as plated the outside of the frame with 1/4" to match the old BC plate. Now I need to modify the frame inserts for the steering box bolts. uploadfromtaptalk1426401894790.jpg uploadfromtaptalk1426401951453.jpg uploadfromtaptalk1426401993017.jpg uploadfromtaptalk1426402030058.jpg uploadfromtaptalk1426402074797.jpg
 

patrickk1

Jr. Member
Joined
Mar 7, 2011
Messages
135
Loc.
Cambridge
Patrickk1- How is your steering column joint angle? Do your joints cycle? this is the only disadvantage i can see from pushing the box back.
I didn't move my box at all. (Corrected in above post). I used a 4x4 f150/bronco quick ratio box with the BC plate. I did not reverse the pitman arm as you do in be 4x4x2 conversion. I did have to shim the bottom of the box with a washer so one of the steering joints would not interfere with the coil tower when I moved the tower forwards. All my steering joint angles are fine. Runs down the highway at 70 perfectly (I'm on 37's.)
 
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
Got the frame inserts finished last weekend. Also welded some thick washers to the other side of the frame.
Got my axles back from the shop yesterday, now the real fun can start.

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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
Radius arm brackets all gone now.

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Drivers and Passengers front frame rails all cleaned up.
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
So I realized I needed to have my new Atlas transfercase installed before I actually start mocking up the axles. So I pulled the old d20 and started installing the atlas. I tried all day to get it to clear both the frame and crossmember but couldn't make it work. I was getting frustrated and about to notch the frame, when I decided to remove the Clocking ring. That's when I noticed it had another position it could bolt to. So the next day I had the atlas installed in an hour. Lesson learned, don't be so damn stubborn.
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Desert Thrasher

Desert Thrasher

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Joined
Jul 14, 2001
Messages
2,353
Next I decided to mock up the new coil-over towers. These are from TMR Customs. They are a little too tall, so I cut the inner fenders out some more. I will have to relocate a few things later, but I like the looks of them poking up into the engine bay.
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68rockcrawler

Bronco Guru
Joined
Sep 18, 2006
Messages
1,417
I'm using a stock Bronco pitman arm, different lengths could be useful. Here is how I braced the body mount and core support as well as plated the outside of the frame with 1/4" to match the old BC plate. Now I need to modify the frame inserts for the steering box bolts. View attachment 360019 View attachment 360020 View attachment 360021 View attachment 360022 View attachment 360023

Wow, it's like dejavu, like I'm looking at my own build! Yours is looking good!
 
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
You have a fully articulated rock crawling wagon? Excellent!.
Almost forgot my wagon was in that pic lol. Yup its double triangulated 4 link front and rear. I built the frame and axles and suspension, then bolted the wagon tub on it. Little coilovers are too stiff but they support a lot of weight.
 
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
I have brand new 37x12.5 cooper discoverer STT. I know it's a little small for what I'm doing but I've only got a few hundred miles on them so they will work until next time for tires. Maybe 39-40s.
 
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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
Got the D60 sitting on jack stands and squared up with plumb bobs off the coilover towers. Need to dial in the caster and pinion angle then attatch the frame mounts for the arms. Wednesday the 2"×.25 wall DOM will be here and I can start building the arms.


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Desert Thrasher

Desert Thrasher

Bronco Guru
Joined
Jul 14, 2001
Messages
2,353
I got the caster dialed in at 4 degree positive and the pinion angle looks good. Next I lined up and tack welded the frame mounts. Then I got a call from the metal supply shop that my 2x.25 DOM is in early, so I picked that up. Wish I would have had time to build the radius arms today but oh well. This weekend for sure. uploadfromtaptalk1428377843390.jpg uploadfromtaptalk1428377884600.jpg uploadfromtaptalk1428377931745.jpg uploadfromtaptalk1428377964638.jpg
 
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Desert Thrasher

Desert Thrasher

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Joined
Jul 14, 2001
Messages
2,353
I got the lower arms all tacked together and the upper driver's arm mocked up. Darn head cold is keeping me from working on it as much as I would like. I had to modify the lower bushings because they are an odd ball size mounting width, 2 7/8". I just shortened the bushings an 1/8" and they fit great. Arms are 2"×.25 wall DOM, and are about 10" longer than stock.
My axle is a 1997 D60 with a Quigley 4x4 van conversion. The upper and lower brackets will work great, but I decided I need to cut down the big flat part of the axle brackets where the old coil cup would sit. Otherwise I wouldn't be able to get more than a 10" coilover. So I will get out the plasma and cut it down. Thinking I will be able to fit a 12-14" coilover now with about a 3.5" lift. uploadfromtaptalk1428896100213.jpg uploadfromtaptalk1428896132761.jpg uploadfromtaptalk1428896168240.jpg uploadfromtaptalk1428896214260.jpg uploadfromtaptalk1428896243980.jpg
 
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