Project: Rockin' Horse

TAWL_BOY · Jul 20, 2013

The name of this build has a double meaning. It will be used to be a mobile display for OCX Adventure Outfitters' CrawlTunes speaker enclosures and have a high wattage marine grade audio setup. Plus, it will be taken all over this area to off-road parks for rock crawling and general trail riding.

I've got a handful of other 4x4s, but none that had a removable top and were in good enough shape and street legal.
So I set out to find a vehicle that met these criteria, and lucked out on this 73 Sport.

I just had a major knee surgery a couple of months ago and I'm still on crutches. So, right now most of this is still in the planning stages.
This forum has been a great resource since I picked up this ride.

Our enclosures' clamps fit 1.5-2" OD tubing. So, the 3" oilfield pipe sport bar won't cut it. Plus I drive this thing 75 down the freeway in Houston and would like a little more protection.

I've done some tube bending in the past...shock hoops, pumpers, and bunch of baskets and raised hunting seats. Since I'm on crutches and don't currently have access to a good bender, I'm gonna outsource a good family style cage to shop around here that's got a great reputation with tube work.

I've already picked up a Wild Horses Extreme Duty Output Shaft, and I've got a BC Broncos dash blank on the way.
I'm gonna be running some 5.25" speakers in the dash for a better sound stage and so I can hear a little better when going freeway speeds.

I've got big plans and a lot to do on this rig, and luckily I've got a good base to start with. But upgrading to power disc brakes, and replacing and upgrading the worn factory power steering.

Please feel free to offer critique my ideas and offer suggestions as this goes on.

Thanks,
Derek
OCX

sprdv1 · Jul 21, 2013

Nice Rig Derek... Look forward to the build.

broncobsession · Jul 21, 2013

You get that out of nacogdoches? I recognize the roll bar. Good luck.

bchesley · Jul 21, 2013

I just purchased a Bailie Bilt family cage and it was only 130 to ship it to Tyler. I am just a few hours north of you so shipping should not be much more. It was the best deal for a fully welded cage ready to bolt in. I also think that its the best overall design and look.

TAWL_BOY · Jul 21, 2013

Thanks. And yes it was from Nacogdoches.
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I think I've got a free(or near free) 5.5" Duff Long arm kit lined out...new in box.
Right now it's got about 3" springs and it's on a set of good 33 Maxxis Bighorns.

Since I really need to upgrade the brakes(especially since my wife wants to drive it), I'll be going with the 5.5" lift and 35s, and this will be played with in the rocks; I'm thinkin' I'm gonna go with a narrowed HP 44 out of a 79 F150.
Once I get another tow rig down the line I'll be going with 37s. And I plan on running ARBs front and rear.

My power steering pump is squealing like a banshee and it doesn't really work well sometimes at idle. Plus the 6 turn box sucks, and it's a little sloppy.
So...I will be doing hydro assist. My old truck was on 46" Baja Claws and I could turn the wheel with my pinky at a stop.

Will a rebuilt 3.5 turn stock box running hydro assist do fine on 37s? or should I get a 4x4x2 box and drill and tap it?

I will be going to a PSC pump.

kb6677 · Jul 21, 2013

Very cool to see a vendor post up on using an eb to show off their products. Hope you will be able to get off the crutches soon. I am a bit confused on the "use" of this project. You mentioned playing on the rocks with 35/37's and a 1/2 ton D44hp. Those two features will limit your play factor depending on driving style. Most folks who really use their rigs "hard" go to D60's and 40"+ tires. Not that you can't have fun with smaller tired and axle rigs. If you plan to stick with the D44 I would highly recommend going to RCV shafts or AT LEAST chromo shafts and 300m or better ujoints. Same on the rear 9, upgrade shafts- 35spline chromo shafts should be fine. Nodular chunk for the 9 is a plus if you have a heavy right foot, a good "hoss" under the hood or both

If you stay with 37's or smaller you will be fine with a 3.5 turn eb box with ram assist. Here is a link to a good source for tapping and converting your 3.5 turn box to ram assist-also in TX.

http://westtexasoffroad.homestead.com/index.html

Below is a link to a very reputable club with members who USE their rigs on the rocks and are familiar with the terrain. I have had the pleasure to ride with some of them over the years -top notch folks and well built rigs. You might want to join and post up on their list as well.

http://www.lonestar-ebc.org/

TAWL_BOY · Jul 21, 2013

The main goal of this rig is to look good displaying my product and to make it play at places like Disney, OK; Hot Springs, AR; and Katemcy, TX.

I want it to stay lookin' fairly nice and it won't get thrashed.
I will be going with 35 spline shafts and I'm thinkin' True Hi-9 in the rear.

I have a Jeep CJ10 on custom built dana 70s front and rear, with full hydro steering, doubler, 4 link rear, on 43" TSL SXs. It's almost done.
It will be for the hardcore stuff, but I decided to expand my business before finishing it and I need a pretty street legal rig to help with marketing.

I've been daily driving this thing all over Houston for the last six weeks. Other than a bad battery and a clogged fuel filter. It's been great...other than brakes and steering(I guess those are important).

TAWL_BOY · Jul 21, 2013

Photo fab resume:

I had better pics on my old phone(God rest it's sole).

By the way I'm selling my cut 54" Boggers on Stazworks Rockwell Double Beadlocks to fund part of this.

DrLathrop · Jul 21, 2013

Join up with LEBC. We would love to have you. There are quite a few bronco owners in the Houston area who would be interested in your products. The annual roundup in April would be a great place to showcase your rig & your products as a vendor sponsor. Welcome to the club.

TAWL_BOY · Jul 21, 2013

Sweet. More info?

I'm planning on making the Oklahoma Classic Bronco Roundup in Hot Springs in Late Sept.

TAWL_BOY · Jul 23, 2013

I'll be doing a dual battery setup with one dedicated to the stereo and winch. I'll be using the stereo a good bit without the vehicle running at event and stuff.

What's the best(simple install) alternator option that that will give me at least 140 amps ditch the external regulator?

TAWL_BOY · Aug 28, 2013

OK, I haven't done anything beside cleaning up some wiring and some general maintenance and repairs.

I'm driving it on the freeway everyday it's supposed to be good weather(got wet a couple times).

I'm gearin' up for my first OCBR. We'll be there with some of our product and wheelin' and hangin' out.
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Thanks to all of y'all that have bought OCX products. Alot of your money goes back into the off roading community. From advertising at parks like the Superlift ORV Park in Hot, Springs, food and lodging in local businesses in wheelin' towns, and other 4x4 vendors....and as of recent Early Bronco Vendors!

I've got in a Wild Horses Extreme Duty Dana 20 Output, and a few other WH bits(their tailgate silencer kit is great), a JB conversions twin stick setup, and a BC Broncos custom dash.

I had the instrument cluster hole move to the other side of the column to make room for some 5.25" speakers in the dash.

I'll run a WH Tach to the right of the instrument cluster.

Soon the cluster will be sent to Classy Chassis Restoration to be restored and upgrade.

I almost went with all aftermarket gauges, but after seeing fallingdown's stuff on the board, I figured I'd stay classic.

Probably won't get this stuff knocked out by the OCBR. I'm just getting back to walking after over 2 months of being on crutches in a full lock out brace.

TAWL_BOY · Oct 2, 2013

I was steadily preparing for the OCBR(I had a great time), I just didn't post anything thing up.

I ditched the stock dash and pulled out the 3" pipe roll bar.

I quickly got lined out to have a simple(for now) cage knocked out in time for the event. More will be added fairly soon.

It gives plenty of head and leg room.

I finally have my product on one of my rigs.

TAWL_BOY · Oct 8, 2013

Some sort of AC compressor bracket was empty on my motor and really in the way of everything.

I got the PSC pump mounted up and the steering box has been sent off to them to be rebuilt with quick ratio steering and drilled and tapped for hydro assist.

Pulled out the old alt. Has Motorcraft and a 15 on it. Original?

I'm slowly cleaning up wiring and stuff and I'm hopefully pickin' up a 79 Bronco this week for $600. I'll I need the axles and I'll part out/scrap the rest.

TAWL_BOY · Nov 9, 2013

I had to make a mount to locate the PSC reservoir the height they recommend.

This is tough with the pump mounted in the factory location.
Just barely clears with the hood shut. But I have the WH 1" lifted body mounts I'll be installing soon.

I got the reservoir with an extra return for when I do hydro boost(soon).

I'm tryin' to figure out what I'm gonna do for axles.
I'm back and forth from day to day. Definitely at least goin' to full width.
Probably gonna do a 9"/14 bolt hybrid in the rear to have full float. Not sure if I want to do a fabricated housing or not.

Part of me says go with a big Bronco or F150 44 and throw some RCVs in it. And just run extended radius arms.
But then I'm thinking of building a 9"/ 60 hybrid for up front. Then I'd end up going 3 link with ORIs.

TAWL_BOY · Apr 10, 2014

I was all geared up to to John Sumner's Big Meats Run in Disney, OK. I've had some parts on the shelf for awhile, and I figured I could make a few upgrades before the run.

I pulled my t-case to install an Advance Adapters Xtreme Output shaft and go ahead and pull the interlock pills for front digs. I'll be running selectable lockers and cutting brakes soon(hopefully).

I quickly decided to cut a hole in the tunnel around the shifter from all I had read from other installing twinsticks, and it would make accessing the t-case adapter bolts a little easier.

I then proceeded to scrape an clean about a 1/2" layer of gunk off the dana 20.
I spent 1 lunch brake pulling the case apart. I carefully kept up with all 48 needle bearings and put them in a plastic bag. I come back 2 days later to reinstall, and I couldn't find of the needle bearing spacer washers.

At this point, I decided to drive my 2.8L Colorado there(26 mpg) and just wheel with some buddy's and vend. It was still fun.
Saw a few nice Bronco's there.

Jason at BC Bronco's was awesome and sent me the part I needed and I got it back together.

Reinstalling the case to the truck WAS NOT FUN by myself. The way my exhaust is made it a pain. I didn't need to go the the gym that day, since I spent 20 minutes pressing that heavy thing.

Then I put in the JB Fab twinsticks. Simple install, but I don't know how you could do it without cutting the floor.

Getting the crossmember attached to the t-case and then back to the frame was difficult.
The Xtreme Output's breather is touching the floor pan(I assume because the body mount's are very worn).

QUESTION:
Is this all going the right way(snubber, bushings, x-member)?

TAWL_BOY · Jan 10, 2015

I'm finally updating this and beginning the real build. I find build threads help keep me on task and provide critique, advice, and get questions answered.

After getting the t-case reinstalled, I threw in one Corbeau suspension seat and harness for the LEBC Roundup in April at K2 Rocks in Mason, TX.

TAWL_BOY · Jan 10, 2015

CrawlTunes has kept me pretty busy over the last several months.

My wife and I attended the Lucas Oil Off Road Expo in Pomona, CA back in October.

It was nice meeting some of y'all. We did very well and had a blast.

I've slowly been collecting parts for my next stage of the build.

Got my Hellfire Fab buggy mirrors. Solves the issue of not running doors.

Viking Panels made me a custom switch panel to my specs.
I went with engraved rocker switches, instead of engraving the panel.
That way I can rearrange and add/delete switches if the need arrises.

Got a Ruffstuff 9" Housing with 35 spline Nodular 3rd with ARB air locker and Dana 60 spindles and hubs.

I got a great deal on a set of Duff Extended Radius arms that had been mounted on a roller but never used.

I got a 79 Bronco front axle that I'll be running for now. I'll be saving funds to do a fabbed 9" front with 1 ton outers.

All my brackets/tabs just showed up from Ruffstuff for my rear 4 link.
I had some link I robbed off my old mud truck that were still in good shape.

I'll be running 14 ORI Struts at all 4 corners.

I'll be stretching the rear 4-5" and, I'm gonna scoot the front axle forward 1" since I'll be doing new radius arm mounts anyway.

TAWL_BOY · Jan 10, 2015

My before reference pic, before any of this started:

I'm assuming theres about a 3" lift on it. It's on 33s.

1st thing that needed to happen was get my WH 1" body lift bushings installed.

My garage is stuffed to the brim, so I backed into the drive way to knock this out. And it's been super cold and rainy lately.

Issue number one was someone floored over the front bolt holes.

I tried my best to use a 1" hole saw to cut a hole right over the bolt head so I could use Jeep floor plugs....I was slightly off and I had to step up to an 1.5" hole and use New Super Duty floor plugs.

Next problem, all 4 of the rear body bolts snapped. The middle of those bolts was pretty corroded and thin.
I had to bust out the Sawz-All.

I got 3 mounts in on the passenger side. I still have been able to remove the bottom of the body mount that's captured over the frame on the mount thats right under the back of the seat.
The end of the bolt is down into the frame hole. I thing I'm gonna have to bust out the blue wrench on this.

With rain coming, I had to push it into the garage by myself with only one side lifted.

This would be cake with if the bolts and mounts weren't in such bad shape.

Any body know the purpose of this bracket on the frame?

NGABronco · Jan 10, 2015

Yes sir, that's for the cable that prevents the spare tire from swinging all the way around!!!

http://shop.broncograveyard.com/Tire-Rack-Safety-Cable/productinfo/15340/

Nice rig you have and are building!!! Good luck!!;D;D

Project: Rockin' Horse

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