Best of both worlds build

[Colo77Bronco]

The build has officially gotten underway. I spent the last 6 months breaking everything down and assembling parts. I have included pictures of everything to this point. I started with a very rusted '73 and stripped it down to the frame and then started with 100% new parts. This is my third Bronco build and I decided to do it my way with everything I ever wished my others had. I knew that if I ever had a Velocity or Icon bronco I would not be happy with the stance as the stock axles are entirely too narrow for modern power and speeds. Also cannot understand why anyone would have all of the shop tools to create anything and they leave the stock wheelbase as well. I do plan on using this vehicle as my daily driver and I want to be safe as well as capable off-road so I am stretching the wheelbase to the maximum I can without completely destroying the body and going full width axles. I got a 2007 F350 front axle and a 2011 F350 rear and stripped them down to clean tubes. We will be doing a 3-link front and 4 link rear with boxed trailing arms and aluminum upper links. Going with Coil carriers and bypass shocks. Running Gen3 Coyote with 10r80, Atlas 3.0 and 4.88 gears. 38” tires but opening fender cutouts to keep center of gravity as low as possible. Was going to go with lower gears but advance adapters recommended strongly against it with the low gears already in the 10R80. Up top is a new tub from Rust Belt Broncos and I was very nervous until it arrived. It came seam sealed and in Epoxy primer so that will save quite a bit of time. The interior will be dynamatted, carpeted, Parchment with nice finished panels and going to upholster the interior of the top as well. From inside, it will be very nice with AC, Dakota Digital gauges, and everything I love about my current 2019 Rubicon. Already have remote start set-up, power windows, power door locks and all of the creature comforts. Jordan Townsend in Colorado Springs is doing all of the fabrication and he builds Ultra 4 race suspensions, hardcore off road rigs, and performance race car suspensions. We should be able to dial this thing in to handle beautifully on the highway and very capable offroad. Also, much safer than anything Icon or Velocity make with the narrow Bronco axles and stock wheelbase. Pictures are day 1 through current progress and frame table covered in bronco parts with the frame and axles. Once the age is done the body will be supported enough to get it on the frame table.

 

[Scoop]

Sounds like a great plan for your build. I did not go full width but I did stretch the wheel base as far as I dared without stretching the body. My goal was 104 inches which I got with the frame stretch and moving the the front forward. It measures about 103 1/2 static on the ground. This is a great wheel base for Colorado and Moab wheeling. Works well for me. What wheel base are you shooting for?

 

[Colo77Bronco]

Did not have a specific goal but 100+.

 

[gnsteam]

Sound like a great build. Following for sure, good luck.

 

[Colo77Bronco]

Got body mated to the frame with the 2" body lift and set the ride height and wheelbase. Got to 97" and to go any further I would have to really butcher the grill and the rear end. Going to do some major fabrication at the rear frame to keep it this low and get 8" of up travel in the suspension but we have it figured out. The front is going to be a more serious challenge due to the pumpkin on the Super Duty Axles being directly below the driver side frame rail. Going to have to be very creative to get that right.

Decided that instead of the gorilla warblers, which cover these cutouts well, I am going to fabricate some tube fenders skinned with sheet metal. I wish they would make two options of the flares with one being cut to body line but still long enough to go down tot eh bottom. I like the body line cut but them just dying into the body a few inches from the bottom just bugs me.

 

[Yeller]

Looking really good!!! The pumpkin clearance issue is why I built a custom chassis for mine, it is a challenge sure. Looking forward to seeing progress.

 

[Madgyver]

watching... i got a ton swap plan also

 

[Colo77Bronco]

Prelim frame modification plan.

I think adding this width from just behind the transfer case forward until the front body mount will allow the Atlas to clock flat and get the driver side wide enough to clear the pumpkin. Then, going a little higher like Yeller did up front should make everything work I hope.

 

[1969]

05+ axles are great! Seems like not many people have put them under EB’s.

 

[Yeller]

That should work. Just be sure your motor and exhaust fits in there, it gets tight fast.

 

[Madgyver]

05+ axles are great! Seems like not many people have put them under EB’s.

View attachment 918195

any stretch here. axle moved forward?

 

[1969]

any stretch here. axle moved forward?

1” forward, have the rear sterling in the factory spot.

 

[Colo77Bronco]

Mine has the front and rear both stretched. Removing and replacing the rear cross member and notching the gas tank for the pumpkin.

 

[Madgyver]

Mine has the front and rear both stretched. Removing and replacing the rear cross member and notching the gas tank for the pumpkin.

we did it on the Firebronco...

 

[Colo77Bronco]

we did it on the Firebronco...

Nice work on that tank!

 

[Colo77Bronco]

Got new measurements today with the new frame plans and it will give me 8" of up travel front and rear. That'll do!

 

[green61bug]

Sounds like a cool build, I will certainly be following along.

 

[Colo77Bronco]

Figured out with mocking up the rear suspension I am going to be able to rework my rear wheel wells and gain about an extra 12" of interior flat floor width between the wheel wells. That is actually huge for rear cargo options moving forward.

For the frame, elected to keep the frame with standard body mounts tucked up high for the rear from the Atlas back. Just behind the atlas going to widen like the diagram all the way to the front. Going to have a symmetric front width wise but asymmetric rise with passenger side utilizing stock rise with a notch for the axle so I maintain my VIN and then the driver side will have a more significant rise similar to Yeller's custom frame. The frame rails will be out where the old inner fenders were which will actually make my fabrication of inner fender liners easier since a the frame itself will be providing a lot of protection. Working around the steering shaft/box will require some creativity but I think it will be worth it to have low COG and 8' of up travel on 38" tires with the 12" of added width for stability.

Should be very similar capability and stance to what Gordon Bailie builds. If you have not watched the videos posted on his site it is super impressive what those things make look super easy.

Also, decided on final design for trailing arms for the lowers in the rear and stout aluminum for the upper links.

 

[Colo77Bronco]

Got the frame chopped and putting it back together today with the modifications to make the suspension work.

Got the atlas clocked flat so we had to put a notch in the floor to tuck it up but it made a huge improvement in driveshaft clearance between the 1350 CV joint on the front output of the Atlas and the 10R80 transmission. Widening the frame helps in so many ways.

With the wider frame rails we dropped the Coyote motor 2" from where it would have mounted with the BC Broncos motor mounts so I can clear the Coyote with stock hood and no body lift. Relocating the front crossmember will make things easier with the coyote as well.

We are able to fit 18" rear coilers and 16" front coilovers while maintaining the lower stance. The challenge up front is the combination of coiler and bypass shock take up some real estate so we are still negotiating that.

 

[Yeller]

What? No pics? Salivating lol.