Hoss Bronco Build - 1972 Modern Wheeler

[hossbronco]

Looks like they are using the “mini” sanden compressor. A few of the ac manufacturers say it doesn’t move enough volume but I never have had an issue with them not freezing the exchanger coil so I think they are fine. All of them I’ve installed I had to raise the coil probe thermostat to keep it from freezing up

Thanks for pointing that out. I’ll ask. I already have a Sanden SD7B10 at home that I’m planning on using, and he knows that, so I think that’s what he’s using, but I’ll confirm. When I first asked him to do this I held my compressor up to my 7.3L to make sure there was room, but I was expecting it to be placed a little closer to the intake.

 

[Yeller]

The SD7 is the mini unit.

 

[hossbronco]

Oh. Thanks for the clarification. That’s what everyone seems to be using. I thought you were referring to the SD5. What other unit would you install?

https://www.sanden.com/pistoncompressors.html

 

[Yeller]

the 508 style is most prevalent with the aftermarket heat/ac kits. Some of those manufacturers do not like the SD7 style, but I've never had an issue and sometimes fitting a 508 is not an option, they are significantly larger in every dimension.

 

[nvrstuk]

I'm learning here, thanks.

Someday, some year I'll need to install AC in Shorty and should have of plenty of room physically & this is good stuff

 

[hossbronco]

I really wanted to hold off on body work, but this is too much rust. This Bronco spent its life in Montana, and it shows. I’m going to have to replace the floors, kick panels, and A pillars at a minimum. The passenger side rocker panel is toast, so I’ll probably use the opportunity to make some rock sliders. The front corner has collision damage that necessitates a new hood and grill. Both front fenders need to be replaced as well, the passenger side due to rust and the driver side , along with the inner fender and wheel well, due to collision damage. The frame looks to be in good shape, other than the front driver body mount being bent. My plan is to tear out the whole front clip and install tubing instead, though I’ll hold off on any suspension changes for now.

The firewall and rear quarters don’t need to be replaced yet, though I may extend the rear wheel wells while I’m already doing everything else. Needless to say I have plenty to work on. I’ll be halfway to a full body replacement by the time I’m done. Part of my just wants to do it all right now, but I’m going to try to resist the temptation.

 

[nvrstuk]

Well, we all know to find you in your shop and nowhere else for the next 2 yrs!!

 

[hossbronco]

Dear goodness I hope not! My goal is to get it to the next LEBC Round Up in Texas a year from now, with the Godzilla, 6R80, and Atlas Pro installed. I’ll probably still be on stock axles with 4.5” of lift and 35s, maybe 37s.

 

[BruiserOutdoors]

sell this tub for 2000, and put it towards a new tub. it will cut years off your build time and save you years of stress. rust sucks!


as you wait for a new tub, you can restore the frame, and install the powertrain.

 

[hossbronco]

My console came in today! I probably should have built my own, but buying it saved me a ton of time. This console looks very much like what I had in my head initially. I’d like to make a few adjustments to it down the road, but I’m very happy with how it turned out.

I considered a Winters or VX shifter, but I like the look and feel of the Lokar, especially with the manual SelectShift pattern, and the Lokar allowed my to install dual Switch-Pros where I can easily reach them when harnessed in. I wanted a dual setup for more buttons and because I don’t trust electronics, so if one unit fails on the trail I can reconfigure them so I still have functioning critical components.

I plan to modify the Lokar shifter so I can quickly go from Drive to Reverse with out having to push the button.

 

[hossbronco]

One of the changes I’d like to make is to extend the pad to the front edge of the lid, leaving a horseshoe-shaped cutout for the lock. I may also extend the shifter because I like to drive with my arm on the pad and my hand on the shifter. I’ll have to see how everything lines up when I install the seats. Also, the cup holders look like they’re going to rattle around, so I’ll add some padding to the outside.

Not shown is the A/C extension unit I purchased, which extends A/C to the rear seats. There’s also a pistol lockbox and shock inside the console. I think I’m going to install the Quick 6 in the front portion under the dash, and there’s supposed to be a magnetic cover somewhere, if I can find it, to cover it up when I don’t want to see it, if ever.

I’d still like to add GMRS and CB radios somewhere and to integrate a rear axle cutting brake with a removable or telescoping handle into the area as well. Both of these will likely happen down the road, once everything is up and running.

 

[nvrstuk]

Where'd you get the console?

Agreed on padding for the forearm on top of the console. I am extending it down the sides some also to help give my wife some relief when wheeling. It sure is much nicer in the summer with short sleeves

 

[hossbronco]

I got the console from BC Broncos. A couple of years ago I drew up my own idea for a console. A month or two later BC came out with their console, and it was very similar to my design, with a few nice upgrades I didn’t think of.

Interestingly, a side pad is one of those upgrades I didn’t get. Now that you mention it, it may be a nice thing to have. I didn’t really care for it for aesthetics, but I could see where I or my passenger would be leaning on it in an off-camber situation, and the padding would be better than hot metal.

 

[nvrstuk]

Passengers have about 2-3" of less space than the driver. That's why the console is such a pita for them (Pain In The Arm).

 

[hossbronco]

I’m starting to make a little progress, though it’s going slower than I’d hoped. I installed the 2” body lift, which was more difficult than anticipated, and am working towards test-fitting the Godzilla and 6R80 in the coming weeks.

I was one of the first to purchase the new low profile Ford Performance intake, but it was a little damaged, so I’m waiting for the replacement to come.

 

[nvrstuk]

Double and triple check ANYthing the neanderthals at FP do!

They shipped my block back and it had water, not antifreeze but standing water in the bottom of the shipping crate. Of course everyone knows about that FP can bore a block to spec either so be careful.

I think their QC is on par with a HS autoshop class average. I've taught HS auto so I have the ability to see the likeness between their abilities.

 

[Oldtimer]

But there is hope for HS autoshop students, They want to learn

 

[hossbronco]

@nvrstuk do you have faith in the design engineers at Ford Performance? It seems like they have some really good parts. This intake is an improvement on the standard intake, and I’m hoping to buy their Megazilla camshaft if it ever comes out.

After seeing what you went through I certainly don’t trust their ability to put things together or fix problems, which makes me reluctant to buy the Megazilla heads when they become available.

 

[nvrstuk]

From what little I know about their design department they seem to have some good ideas - - but coming to fruition ??? I do know that they put rather small heads on a 460ci stroker. Their Z heads have tons of good parts (like the block) but a 460 block should have 225 heads but Ford doesn't make any so they choked it with their own brand. Just a thought.

IF you don't need the heads right away maybe wait for Trick FLow or AFR to come through.

 

[hossbronco]

That’s a great idea. I’ve been considering replacing rods and pistons, but maybe I should wait until stroker kits come out as well. I’m not sure how much I gain at this point by going to forged pistons, and it probably doesn’t justify the cost. I’m willing to bet the stock pistons will hold up to 615 hp.

I’ve been trying to mimic the Megazilla performance. FP is saying it will make over 500 lb-ft from 2,500-6,000 RPM, with peak torque of 640 lb-ft at 3,800 RPM and 615 HP at 5,800 RPM. These numbers are much better than I’ve seen elsewhere, so I’m hoping they’re accurate, but this is why I’ve been looking at FP cam and heads.