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Project Nebula - James Duff

ThatGuy@Duff's

Sponsor/Vendor
Joined
Feb 26, 2018
Messages
24
Loc.
Knoxville
We're getting ready for the big show next month and we're taking the opportunity to update our LUBR, Nebula, to our Dual Sport 2.5" Four Link Performance Package.

Last year we installed our LUBR 1.5" system which had a great look and drove great, but @jduffent Suzy said: "Nebula needs a TUFF update", and our sales staff needs reference to know what our four-link system is like on a Bronco. So here we are... :)

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Before we break off into talking about the four-link system and answering those questions. I want to take a few moments to talk about our 1.5" systems and why we brought them to the market a couple of years ago.

The 1.5" performance package is great for LUBR owners who are planning a coyote with a stock frame and want the truck to be as low as possible. Since the coyote powertrain requires a 2" body lift. This will allow you to have 3.5" of total lift. I don't know about you all but my knees surely appreciate not having to jump down out of a Bronco that's 10 feet up in the air. Plus the 1.5" lift also keeps you from having to make drastic changes with your steering geometry. Over the past few years as I've managed our sales team, the 1.5" and 2.5" systems have been our top seller because they keep the geometry in check, and our recipe of parts allows for you to have the confidence to throw your keys to the wife and expect it to have the road manners of a modern vehicle.

Now with Nebula, there are no plans to go with a coyote, we're keeping her true to the Bronco roots with a normal pushrod windsor. In this first phase, we'll be installing the Performance Package, power steering, and the power brake system that we've sold for years. We'll also be installing a fresh set of 10.50" wide BFG ko2 or ko3's on the factory wheels.

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In phase 2 we'll likely be installing an automatic transmission c4 or 4r70w along with air conditioning so we can make this a nice year-around cruiser.

Nebula's current powertrain is a Roller 302 with a 3-speed & Dana 20. Dana 44 front axle and banjo housing 9" rear axle. It has a stock-sized tire on the factory wheels. We coined the term "Nebula" from the Marvel character that complements her shade of Duff Blue that Suzy picked out herself. For those who aren't a comic book nerd, Nebula was somewhat of a cyborg made of bits and pieces to do her job in the multiverse. After our Nebula was restored we made modifications to the frame to allow us to modulate her with several different types of suspension bits whether it's hoops, towers, or a factory shock mount, and allow us to revert to her being a leaf-sprung Bronco in the future if we deem necessary. She was restored to be a cornerstone Bronco in the stable and to be used as a test bed for new and upcoming parts, some of which you all will be the first to learn about in this thread.

I invite all of you to not only follow along here but on our Facebook and Instagram pages. @Monster Mike is standing by too with any questions you might have as he and our team film the installation of the system for Bronco Garage.

I look forward to showing more as things evolve over the next 45 days. This is going to be super exciting. See you all at the show.

-Zac at James Duff
 
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ThatGuy@Duff's

ThatGuy@Duff's

Sponsor/Vendor
Joined
Feb 26, 2018
Messages
24
Loc.
Knoxville
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Brian and Easton are making quick work of the front end. But they've installed the T-Rex arms, extended shock towers, MS2020's, coil springs, steering, track bar and front sway bar.

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Above you can see our proprietary HD lower coil retainer with the sway bar mount for the hellwig sway bars. This keeps from lifting the front end a 1/4" inch and allows you to install either our 5/8" bolts or quick disconnect pins.

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Great geometry, the track bar and drag link are parallel.

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If you've seen our install videos of the Dual Sport steering system or are looking to install this system, it's very important that you use the correct adjustment bar for the drag link. It has a cut on the adjustment bar to allow for the u-bolt for the stabilizer to be installed.

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More shots of our Lower Coil Retainers, and our no drill hardware for the knuckles.

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The rear axle on the stand is getting prepared for the removal of the shock mounts.

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All the 4-Link goodies laid out on the table. Of course we had to go with Duff Signature Blue.

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Sway bar hardware.

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The unique part about the Dual Sport 4-Link is the dual synergy poly bushings, which allows for great road manners for a mostly street-driven Bronco like this one will be.

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Rear bump stops and mounting plates.

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Driver side front suspension. We'll be installing the Monster Disc brakes soon.

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Rear axle removed from the Bronco. Leafs and the rest to be removed soon.

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Factory tires waiting on new rubber.

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Duffinitely not a Duff exhaust :cool:, we've got something in store for this one though. Also removed the rear Hellwig sway bar as it won't be of use with the 4-Link, we'll be installing our 4-Link Specific rear sway bar.

More updates to come, Brian is currently working on the rear axle prep as I type this out.
 
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ThatGuy@Duff's

ThatGuy@Duff's

Sponsor/Vendor
Joined
Feb 26, 2018
Messages
24
Loc.
Knoxville
Looking forward to following this one!

Todd Z.
We are too Todd. We've debated for a while on which Bronco got the four link, this one made the most sense. I think it's going to have a great look and the LUBR guys should enjoy it too.

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The truss is mocked up on the banjo housing we had set aside. As a salesperson one of the questions I get all the time is why can't I purchase this bare? Well for us we make these in batches and some configurations, like the "centurion" housing truss don't move as fast, and we don't want parts rusting away on the shelf, so we have them powder coated and it makes for a good base coat if you decide to paint or powder coat in the future. As you can see Brian has carefully scrubbed the powder coat off strategically to get it mocked up.

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Frame mounts and leaf springs removed and set aside for our next project.

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hsach

Contributor
Members Only
Joined
Apr 19, 2013
Messages
390
Cool project, I will be interested in how you route the exhaust. Have you decided on single or dual?
 
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ThatGuy@Duff's

ThatGuy@Duff's

Sponsor/Vendor
Joined
Feb 26, 2018
Messages
24
Loc.
Knoxville
Cool project, I will be interested in how you route the exhaust. Have you decided on single or dual?
We have an exhaust kit that we're doing our final testing on with this install. I will show it off as we get to that point in the build. It's a 2 into 1, or 2 into 1 into 2 set up as there is limited room. Hopefully it passes all the tests and we can offer it to the public. Details to come.
 
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ThatGuy@Duff's

ThatGuy@Duff's

Sponsor/Vendor
Joined
Feb 26, 2018
Messages
24
Loc.
Knoxville
Alright, I was away from the shop on vacation last week, so I'm using the photos that Brian and Easton took while they continued the installation in place of my absence. I snapped some photos of its current state.

While I was out Brian tacked up all of the mounts and did a bump test to make sure everything was going to clear as expected. Also our 33x10.50 KO2's came in, BFG doesn't offer a 33x10.50 in the KO3 yet, and we can't wait until summer time, so back to the tried and true with the white letters out.

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As you can see with some patience and skill you can easily match the powder coat without having to strip the entire truss and axle, Brian will be finishing up the paint job once everything is road-tested. He also found that the wrong wheel cylinders were installed in the rear drums so that's being tended to.
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Now after the truss was completely burned in Brian checked the trueness of the axle and found that it was over a half inch out, the axle wasn't straight even before putting the truss on, so out came the torch and our tools to get everything straight so we don't have to worry about eating bearings on this small bearing axle housing.

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There are no coil springs in the Bronco in the photos above, and from my understanding, the Bronco will experience full coil bind before ever stuffing this much tire.

This is where we are currently. We'll update you more later this week when we get the Bronco out in the sun for some photos. I can say it's looking really nice, I think after putting a C4 in it later this year and some AC it's going to be a hit at the local cruise in's and the events we travel to.

After we finish up the four-link, we'll move on to our power steering conversion, exhaust, and Monster Front Disc Conversion.
 
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ThatGuy@Duff's

ThatGuy@Duff's

Sponsor/Vendor
Joined
Feb 26, 2018
Messages
24
Loc.
Knoxville
Few more shots from today below. Brian said it should be ready to stay on the ground after today. All that was left for the 4-Link was the sway bar and rear brake lines. Hope to get it out in the back yard for some photos this week. Then he'll be moving on to the power steering conversion and disc brake conversion. We also have sent the drive shaft off to have it updated.

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Brian also trimmed up the tub so that it fits over the coil bucket better. Also, it's about 3/4" high in the rear right now without a full tank of gas or our spare tire carrier mounted. Should be level once that's in place. We're not sure if the spare will be on for the show or not as we have to have the tire carrier and spare painted. More progress to come. Let us know if you have any questions.

P.S. If you want to learn more about our performance packages and what all that entails, check out this article I wrote today: https://dufftuff.com/what-is-a-performance-package/
 
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ThatGuy@Duff's

ThatGuy@Duff's

Sponsor/Vendor
Joined
Feb 26, 2018
Messages
24
Loc.
Knoxville
Alright guys she's on her feet, shes running good and sounds good. Now to put some miles on her this week and test and tune.

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Brian is putting it back on the lift I will get some shots of the exhaust, let me know if there's anything else you'd like to see.
See you all at the big show next week. Last chance for orders to be placed to pick up at the show is tomorrow.
 

.94 OR

Contributor
Bronco Guru
Joined
Jul 5, 2009
Messages
1,845
I vote for some small hub caps. Bronco looks good but the wheels just look a tad unfinished for me.
Interior shots?
 

Glass Pony

Contributor
Bronco Guru
Joined
Feb 13, 2012
Messages
1,870
Loc.
Sussex County Delaware
Awesome build! Looks like a sleeper. As a fan of the Duff blue suspension parts I have a question, "what color blue paint do you use when finished welding on the blue powder coated parts?"
 
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