Hey Dan. Yep, looks like you're right about a lot of work! But lots of help here, and yours is certainly not the roughest that's crossed these pages.
Not interested in running the Explorer stuff instead?
Not that there's anything wrong with the Explorer stuff, but I've wanted to build an engine with aluminum heads for a while. I figure the 50lbs or so of weight savings and a little better resistance to detonation justify it. At least it will to my wife anyhow.
Are there adapters now for the newer transmissions to the older engines?
Good mileage is achievable, but it ain't easy!
Yes, I've found a couple of adapter plates for bolting up a 302/351 to a 6R80.
But you will restore and update it, correct? The wheel bearings need to be replaced no matter what else you do.
BEFORE you drive it much!
Sounds like that won't be a problem, as you're going through this head to toe. But I had to mention it since it's a weak link (so to speak). Not that it was a bad, or weak design. Just that they're potentially 50+ years old!
Yes! I plan on rebuilding the rear end and the Dana 20. I can't stand the thought of not going through everything. I'd hate to work on this thing for a few years and then the time comes to finally start driving it and immediately have to park it to fix it.
2.5" suspension lift and 1" body? Not 100% on that
But it's a good combo, if you decide to go that route. Don't ignore steering linkage mods though, just because you have a shorter lift. Between the lift and the new steering box with a different location you'll be needing to tweak your steering. So mocking things up while building is a good idea.
I like that combo for looks. I'll probably go that route and run 33s.
The 4x4x2 is hell for stout, but is it the best choice? What size tires are you planning? What kind of use are you going to put the rig to? There are newer swaps that can be "better" in some ways. Up to you though, and any of them can be made to work with what you've got.
It probably isn't the best choice for me in all honesty. I don't plan on doing any rock crawling and the closest it'll ever come to doing anything off-roading will likely be some forestry service roads. I do like the 4x4x2 for two reasons though...I've already bought the required steering gears, and it uses Ford parts.
Planning on a whole new body from Dennis Carpenter
A few other companies out there making them too nowadays. Make sure to read the different discussion threads about new bodies in general.
I've read through some of the posts on here about other builders. I was leaning toward one (which I won't name) until I read some reviews. Apparently they talk a good game. Plus, Concord, NC is close enough to drive to and pick it up without having to worry about shipping.
Add disc brakes from a late 70s Bronco or F-150 4x4
That's my preferred brake too. The GM conversions are nice, but the Ford stuff is cool and it's still Ford. Not a purist by any means, but it's nice to keep it all the same brand when you can I feel.
It's another area that requires you to modify the steering linkage slightly, but the parts are there and easy to work with.
Rear disc brakes from Explorer?
Maybe. Not sure how easy it is to convert on a '72 9", and the '74/'75 small bearings are the more desired ones I think. But others will know more of what it takes. Hopefully it's an easy swap.
I'm not well read enough to know how to go about making it happen. I may use another setup or even buy a kit for the rear brakes. Or I may just make a junkyard trip, come back with something and figure out how to make it work.
One thing you'll likely note early on is the inconsistency of Broncos compared to your other vehicles, including your Mustangs. Broncos were orphans inside the Ford stable and didn't get the love that other vehicles did. On the one hand they're very simple, but on the other hand that does not mean that adding, swapping, fixing, replacing or patching is going to be any easier. At least not in ever case.
Best of luck!
paul
