Baja or Bust Build Thread

[sprdv1]

Got a large package from PCI today...helmets, radio, intercom, race air, hoses...

Safety first, that's for sure..

 

[Swerve]

Mounted the emergency brake handle...

 

[Swerve]

Front axle from Currie showed up...nick of paint and then final install next weekend...

 

[Swerve]

Got some paint on it...

 

[BajaBronco]

really awesome! Now that Norra is over I'm really hoping we can come support you somehow in November....

 

[Swerve]

really awesome! Now that Norra is over I'm really hoping we can come support you somehow in November....

Thanks! I appreciate all the help that I can get!

 

[Swerve]

Front axle in (ball busting work doing it by myself!)...track bar in...migs coil cups...tie rod on (may go tro later)...rotors on...fairly productive day. (No making fun of my precarious jack stands)

 

[Swerve]

My wheel spacers came today, so front wheels and tires on, and it rolls again! Coil springs shoved in tentatively to start figuring shock mounts and shock length. So far no Bronco lean at the front...

 

[tasker]

looking good dave!! soon!

 

[Bukin 67]

It rolls again, cool! Enjoying the thread. Keep up the good work!

 

[Swerve]

Thanks guys!

I removed the rear axle today for some final details. I tapped the bottom for a small, flush fitting drain plug.

When I first ordered the rear axle housing, the advert stated that the center part was made from 1/4" steel. However, they neglected to include that the rear cover part of the center housing was not 1/4". The rear cover section is the same thin sheet metal as on a stock housing. After talking with them on the phone they told me that they did in fact make a thicker rear cover section and they sent one to me for free.

Today I finally got around to cutting, fitting and welding the thicker cover piece right on top of the existing thinner one, it is sort of laminated now. I didn't bother doing the section above the back brace as I figured that area should be out of harms way, I hope!

Got paint on my Wrap Trap and rattle canned the housing for good measure...

 

[Swerve]

Not the best photos but the short block is mostly assembled, engine should be finished and dyno'ed in a couple of weeks...

 

[migs]

nice progress, keep up the good work!

 

[Swerve]

Thanks migs! I also got the rear backing plates dressed...

These are stock '76 rears, but they are no longer self adjusting, just my personal preference...

The spring between the bottom of the shoes that holds the adjuster is actually from a spring kit for '57 Chevy front, in case someone else was interested in converting their own from self adjusting...

 

[broncoitis]

Looking good! Not sure how I missed this build! Gonna be fun when its done.

 

[Swerve]

Thanks broncoitis...

I installed the center section for hopefully the last time. It's a Mosher Wavetrac, 4:88 to 1. The Warn full float axle shafts, spindles, seals, and the brake backing plates are all on. The rear housing is back under the leaf springs. The Wrap Trap is back in but it will need final adjustment later. I ran out of wheel bearing grease or it would be rolling again...A trip to NAPA in the morning will cure that...

 

[sprdv1]

be done before ya know it..

 

[Swerve]

I installed the parking brake cables and tentatively fabled up my parking brake system. Still some minor details to iron out, but it is functional as is. I assembled both rear Warn full float hub assemblies and installed the Warn premium locking hubs. Final torque on rear leaf spring u-bolts...Found out that I will need to get longer wheel studs on my spacers...two steps forward, one step back!

 

[Swerve]

Today was mostly figuring out my front coil mounting. I used migs coil cups, and then I added 8 degree shims under them to get my coil springs nice and straight. This meant that I needed an 8 degree "washer" so the two coil cup bolt heads could seat flush. I bought a second pair of 8 degree shims and I cut one of them down the middle, tack welded them in place and through drilled.

For the top I made my own upper retainers from 3/16 steel. Much stronger than stock. I made them a little bit wider than stock as well, and I used 7/16 grade 8 hardware. I reinforced the lip with 1/8 steel too. Still some trimming left to do.

I radiused the upper track bar mount gussets that I had installed earlier. Pitman arm now has plenty of clearance. Later if I decide to go TRO I may need to do some more clearance.

Cleaned and painted my bell housing...

 

[Swerve]

Stopped by the machine shop on my way home...cylinder heads are ready for assembly...drilled and tapped for screw in rocker studs...

Fedex brought my carb hat today. I eventually plan on a snorkel type air intake, but it is still in the development stage...