4x4x2 Conversion Questions

[FordBronc]

Using 1/4 material for the top and side plate, that way I do not need to get crazy with a T brace of the flat lay out. Radiator is aluminium.

Looking into a lower sector shaft brace idea...but one mod at at time. I read a CB forum statement that is might NOT be a good idea, a guy thinks it caused him to blow a lower seal??

Yes body mounts are tired and that front dvrs side frame bracket area took a hit when the PO had it. P/S box mount frame area is braced/overlayed on both sides already, just a shoddy PO job I need to clean up.

I appreciate your input and follow along of this thread. Sorry to EarlyBronc74 for hijacking your thread. I have posted the correct seal part #'s.

 

[Rustytruck]

James duff made the truss.

http://www.emotoman.com/steering/psteering.htm

 

[FordBronc]

Just off the phone with them, seems like they do not sale that specific part. And it is not part of that p/s conversion kit either.

The sales guy is going to ask Suzie to she if they do sale it.

 

[Rustytruck]

If they didn't make it then they got it from AGR since the rest of the system came from them. Its back in the era of old man Duff running the place. anyone have a 10 year old duff catalog?

 

[FordBronc]

You mean these folks? http://www.steerco.com/ Maybe a long time ago, but nothing on their site now. Thanks for the info and lead on them.

 

[FordBronc]

Got my side plate (paper pattern) and actual metal piece made and drilled to bolt to the frame (by the p/s box mount hdwr).

Some how in the lay out, once the side plate was hard bolted in place, my top plate came up short. So making a longer one of them tomorrow, then should get it welded up.

The process was made more difficult by the PO installed 2" angle iron piece welded in between the frame horns as a stiffener. It seemed to be right in the way all day.

I will use longer threaded studs for the actual p/s box. And still thinking about a vertical T brace on the side plate.

Also looking into figuring out a "truss" for the sector shaft area and a shield or guard/skid plate to protect the front and bottom of the pitman arm and still let the pitman arm move normal.

 

[BRONCO635]

This is the kit WCB sold me back few years ago when I did my conversion.

Sent from my iPhone using Tapatalk

 

[FordBronc]

Remade my top plate longer and welded it up, will post some pics once I get some Ford blue paint on it.

Then will do the bolt to stud swap on the new box, mount it, the brace and bleed it.

 

[jduffent]

Just off the phone with them, seems like they do not sale that specific part. And it is not part of that p/s conversion kit either.

The sales guy is going to ask Suzie to she if they do sale it.

Yep, we've got a few stashed that the guys didn't know about. Tell them you want 007-3225 $34.95 Not advertised since we don't carry those boxes anymore.

 

[FordBronc]

Thank you X1000 for the heads up, the sales rep called me today with the exact info and I have one on order.

Pics when its mounted for sure.

 

[DirtDonk]

Get 'em while they're hot!
And while you can...;D

Paul

 

[FordBronc]

Actually I should of ordered 2, I have the tube buggy to think about.

 

[bronconut73]

I believe Borgeson and Superlift made that ps box brace (that supported the "snout") for the 90's Dodge full size trucks.

 

[FordBronc]

Well....got the truss, got it mock up mounted using the old p/s gear box. Drilled my frame rail and inner bracket I built for the 4th bolt.

Mounted the new rebuilt box, tight bolted it all and marked the spot to drill on the new GB. Looks like I will NOT be drilling the 4th hole, not enough material after I drill. So it will get mounted with the 3 OEM bolt holes.

I loose test fit it to the new box and all looked ok, then after a tight bolt test the plan went south.

Since I already drilled the frame, I do not want to weld up and redrill the bracket, which would move the hole on the bracket further away from the edge. Which in turn would let me drill the 4th hole in the GB housing. Or at least give me more real estate to drill in.

Pardon the PO frame hack and yes the body mount bracket is bent.

 

[Apogee]

Looks good. You could slot the truss and run a socket head cap screw instead of a hex head if you wanted to run a fourth fastener.

 

[FordBronc]

Box has no movement, truss has no moment, I could step down the 4th bolt size and try to get away from the edge a bit?

Redrilling the frame, PO installed inner and outer frame reinforcement flat plates AND my new brace plate. I'd bet will not work.

Any advice on drilling cast?

 

[PDQ]

I am jealous of your fab skills and love what you're doing. After following this I was also able to grab one of the rare box trusses, but that made me look a little closer. If you already knew this, then I apologize, but based on the title of your post and the challenge in finding seals, I don't think that's a 4x4x2 box. Those have gussets on the shaft case which would not allow the Duff truss to fit and the ports are on the bottom of the case. You appear to have a stock bronco p/s box, or maybe a different year/ gen of a 4x4x2 box, or?
Again, if this is "no kidding", then I'm sorry for the pointing out the obvious, but if not, I know I have chased many rabbits trying to decipher mods on my project, so I hope it helps.

The picture attached is a 4x4x2 box where you can see the one gusset and the bottom ports. If you zoom in you should be able to see the other gusset.

Hope it helps.

 

[FordBronc]

Fab skill-less. lol Yes I am using a Saginaw 76/77 OEM power steering box and not the F150 4x4x2 box. Maybe the truss fits the F150 box better and you have enough room to drill the 4th hole?

I never meant to high jack this thread so much, I was about to go down the 4x4x2 road and then got a replacement box for cheap and it snow balled with the inner brace bracket build.

I only wanted to make people aware that there is a chance that the truss will not work on a 76/77 OEM p/s box. At least drilling the 4th bolt hole might not work.

 

[FordBronc]

To get the Duffs outer "truss", tell them you want part # 007-3225 $34.95 Not advertised on line.

Finished the inner brace bracket build and got it and the outer truss all installed.

Now I have to source some new aluminium radiator mount brackets...always something.

Still have some frame clean up to do...

 

[toddz69]

I've never seen the one that fits inside the frame. Interesting piece.

Todd Z.