- Joined
- Jun 1, 2007
- Messages
- 344
This is the build thread for my 1972 Bronco Sport Explorer. The goal is to make this into a modernized offroading machine. In summary, here are the build specs:
7.3L Godzilla (645 lb-ft @ 3,900 RPM, 630 HP @ 5,900 RPM), 6R80, Atlas Pro 3.0, 609 Front Axle (Kingpin, 40 Spline Big Bell RCVs, HP10, ARB, 5.14 Gears), 14 Bolt Rear Axle (40 Spline, ARB, 5.13 Gears), 40 Inch MT Baja Boss M/T
I apologize in advance as progress is going to be slow on this, and I’ll probably worry about the body last, at least where I can.
Here’s what I’m planning. I’ve marked the things I already have with a dash. The rest is either on order or still being considered. Also, please note that I’ve decided to put 37 inch tires on and beef up the rear axle some so I can wheel it while I build out the suspension and full-width axles.
Engine:
-7.3L Godzilla
OBR Controller (Controls Oil Pressure)
-Ford Performance Low Profile Intake Manifold
-Ford Performance GT500 92 mm Throttle Body
-BTR Camshaft with VCT Limiter at 8 Degrees
Johnson Reduced Travel Lifters with Link Bars & Axle Oiling (2126LSR)
Manton 504 Pushrods
Ported and Polished Heads (Future)
PAC Springs
BTR Spring Guides, Retainers, and Keepers
-ARP2000 Head Studs
Swiftek Billet Valve Covers and Coil Covers
Indy Billet Fuel Rails with Mast Cross Over
53 LB/HR Injectors
Callies Heat Treated Billet 4140 Main Caps (Future)
-ARP2000 Main Studs
Mahle Bearings (Future)
Callie’s Forged Ultra H-Beam Connecting Rods with H11 Bolts (Future)
Mahle 2618 Forged Pistons (Future)
Mahle Piston Rings (Future)
-Holley Timing Chain Cover
-Holley Front Accessory Drive
Double Roller Timing Chain (Future, When Available)
-Innovators West Crankshaft Damper
-Dailey Dry Sump Oil Pan (Billet 6061 T6 Aluminum) and 5 Stage Pump
Upgraded Ignition Wires
K&N Air Filter Wrap
-DC Power Billet 270 Amp Alternator
-Optima Yellow Top DH6 Battery (Future: Dual Odyssey Extreme Batteries)
Transmission:
-Gen 2 6R80 Transmission
-GPZ Frictions and PBH Steels
-Modified Center Support
-Billet 300M Intermediate Shaft
-Billet 300M Forward Shaft
-Billet Forward Planetary
-Gen 3 Billet One Way Low Reverse Clutch
-Upgraded Pump Bearings
-Superior STL009 Sure-Cool Cooler Flow Control Valve
B&M 7 Qt. Transmission Pan
-Lokar Shifter (Future: Modified for Quick Reverse)
-Gen2 Quick 6 Controller with Remote OLED Display
Transfer Case:
-Atlas Pro 3.0 Transfer Case (Clocked Horizontal)
-Long Input Shaft
-Short Tailhousing with 300M Output Shaft
-1300 Series Flange Front and Rear
-JB Custom Fabrication Twin Stick Cable Shifter
JE Reel 1410 CV Canyon Crawler Driveshafts
Current Front Axle:
-Dana 44
-Disc Brakes
4.88 Gears
Chromoly Shafts
-Warn Premium Manual Hubs
Future Front Axle (Stretched):
Spidertrax 609 4” 4130 Chromoly (69.25” Wide)
Gearworks HP10 3rd Member (3.812” Case)
5.14 US Gear Shot Peened, REM Polished 10” 9310 Ring and Pinion
ARB RD249CE Competition Air Locker
Tubeworks Duplx Pinion Support
Billet 1480 Drive Shaft Yoke
WFO High Pinion Diff Guard
40 Spline Gun Drilled Big Bell RCV Shafts
Stub Shafts Splined to Direct-Fit Super-60 Unit Bearings
8 on 6-1/2” Bolt Pattern
Reid Racing Super Kingpin Knuckles
Artec Ram Mount
Artec Upper Truss
Current Rear Axle:
-WH Super 9 Housing (large bearing billet ends, 3"x0.250" tubes)
-Weld-On 3/16" Center Section Skid Plate
35 Spline 1541-H Alloy Axles
Timken SET20 Tapered Roller Bearings
-WH Wrap Trap
Third Member - 35 Spline ARB, Yukon 4.86 Gears, 3.250 Nodular Iron Dropout, 6061 Daytona Pinion Support
Stretched 1.25"
Future Rear Axle (Stretched):
14 Bolt
5.13 Gears
Billet 1480 Yoke
40 Spline Gun Drilled 300M Shafts
Super-60 Unit Bearings
8 on 6-1/2” Bolt Pattern
Future Steering:
-PSC High-Flow CBR Power Steering Pump
PSC 6061T6 Aluminum Remote Reservoir (with Radial Dynamics Cap and PSC Anti-Splash Valve?); or Radial Dynamics Remote Reservoir
PSC Hydraulic Assist
4x4x2 Power Steering Conversion
Busted Knuckle 7075-T6 Aluminum Drag Link and Tie Rod (Not RPM Steering; Rock Krawler? Busted Knuckle?)
-Ididit Tilt Column Black Powder Coated
-WH Custom Lower Steering Shaft
-WH Mark 9 GT Black Steering Wheel with Leather Wrap
Brakes:
-Wild Horses MOAB Hydroboost System
-Wilwood Master Cylinder
Wilwood or Camburg Cutting Brake (Future)
Wilwood 6 Piston Disc Front and Rear (Future)
Wilwood Electric Parking Brake (Future)
-Disc Front and Rear (Current)
Fluids / Cooling:
-Ron Davis Radiator
-SPAL 19” Brushless Fan, IP68
-Lingenfelter Fan Controller
-Derale Fanned Transmission Cooler
Custom Peterson 3 Gal. Dry Sump Tank
-Peterson Vacuum Regulator
-Peterson Pop-Off Valve
Setrab Fanned ProLine Oil Cooler with Susa Temperature Regulator
Clear View Filtration?
Oil Catch Can
Power Steering Fluid Cooler
PSC RV00 Vented Catch Cans with Rollover Valves (ARA1?)
-M1A1 Stainless Steel Fuel Tank
Discriminator Valve (Gasoline Evap System)
Vapor Trapper
Exhaust:
304 SS Ceramic Headers (3/8” Flange, 2” Primaries, 3” Collectors)
Borla ProXS 304 Stainless Steel Mufflers
3” 304 SS Exhaust
Exhaust Cutouts, Vacuum-Actuated (QTP?)
Suspension:
4-Link Front with Trac Bar and 16” King Coilovers 2.5 with SDi E-CLIK Remote Reservoirs
Double Triangulated 4-Link Rear with 16” King Coilovers 2.5 with SDi E-CLIK Remote Reservoirs
Busted Knuckle 7075-T6 Aluminum Link Bars
-2” Body Lift
Spidertrax Sway Bars (7075-T6 Arms, 300M Shafts)
Tires and Wheels:
37x12.50-17LT Mickey Thompson Baja Boss M/T (Future: 40x13.50-17LT)
17”x9” Baja Built Outlaw Forged Aluminum Beadlock Wheels, 8 on 6.5”
Exterior:
Metallic Pearl Blue Paint
Custom Full Roll Cage (Behind Dash)
Custom Prerunner Bumpers
Custom Sliders (Trimmed Rocker Panels)
Aluminum Skid Plates with UHMW
-Heavy Duty Wipers
-HID Projectors Halo Black Series Switchback Headlights
-Alice Turn Signal Mod
Warn Suckdown Winch
Rear Warn Winch
-Rear Quarter Panel Guards
-Upper Quarter Panel Guards
-SS Quick Remove Door Hinges
Door Checks
Optional Tube Doors
Hyperformance Tough Windshield
-Black Diamond Rampage Soft Top
Mike’s Metal Worx Wing Vent Window Delete
Extended Wheel Wells
Baja Designs Lights
Tailgate Assist
CJ7 Side Mirrors
Interior:
-Black Leather Corbeau Baja XRS Suspension Seats with Heaters and Lumbar Support (Future: Perforated Full Grain Brown Leather with Seat Coolers)
-Black Leather Corbeau 40” Baja Bench with Head Rests & Heater (Future: Perforated Full Grain Brown Leather with Seat Coolers)
Retractable Seat Belts (Future: Optional 5-Point Harnesses Front & 4-Point Harnesses Rear)
-BC Broncos Console
Fuel Pump Access Panel
-Rosen Aircraft Sun Visors
Electronics:
-Painless Performance Wiring Harness
-Custom Dakota Digital HDX-2014 Gauges
Dakota Digital Cruise Control
-Dakota Digital GPS with Remote Antenna and Ambient Air Temperature
-Vintage Air A/C Front and Rear
-Dakota Digital Climate Control
-iPad Mini 6 Dash
Digital Signal Processor
Backup Camera
-Dual Switch Pros SP-9100
Custom Digital Guard Dawg Keyless System
Speakers (JL Audio C2-650X?)
Two 12” Subwoofers
CB Radio
GMRS Radio
110V Inverter
-Heavy-Duty Synchronized Electric Wipers
ARB On-Board Twin High Performance Air Compressor
-Power Locks and Windows
Other Equipment:
AGM Jack
7.3L Godzilla (645 lb-ft @ 3,900 RPM, 630 HP @ 5,900 RPM), 6R80, Atlas Pro 3.0, 609 Front Axle (Kingpin, 40 Spline Big Bell RCVs, HP10, ARB, 5.14 Gears), 14 Bolt Rear Axle (40 Spline, ARB, 5.13 Gears), 40 Inch MT Baja Boss M/T
I apologize in advance as progress is going to be slow on this, and I’ll probably worry about the body last, at least where I can.
Here’s what I’m planning. I’ve marked the things I already have with a dash. The rest is either on order or still being considered. Also, please note that I’ve decided to put 37 inch tires on and beef up the rear axle some so I can wheel it while I build out the suspension and full-width axles.
Engine:
-7.3L Godzilla
OBR Controller (Controls Oil Pressure)
-Ford Performance Low Profile Intake Manifold
-Ford Performance GT500 92 mm Throttle Body
-BTR Camshaft with VCT Limiter at 8 Degrees
Johnson Reduced Travel Lifters with Link Bars & Axle Oiling (2126LSR)
Manton 504 Pushrods
Ported and Polished Heads (Future)
PAC Springs
BTR Spring Guides, Retainers, and Keepers
-ARP2000 Head Studs
Swiftek Billet Valve Covers and Coil Covers
Indy Billet Fuel Rails with Mast Cross Over
53 LB/HR Injectors
Callies Heat Treated Billet 4140 Main Caps (Future)
-ARP2000 Main Studs
Mahle Bearings (Future)
Callie’s Forged Ultra H-Beam Connecting Rods with H11 Bolts (Future)
Mahle 2618 Forged Pistons (Future)
Mahle Piston Rings (Future)
-Holley Timing Chain Cover
-Holley Front Accessory Drive
Double Roller Timing Chain (Future, When Available)
-Innovators West Crankshaft Damper
-Dailey Dry Sump Oil Pan (Billet 6061 T6 Aluminum) and 5 Stage Pump
Upgraded Ignition Wires
K&N Air Filter Wrap
-DC Power Billet 270 Amp Alternator
-Optima Yellow Top DH6 Battery (Future: Dual Odyssey Extreme Batteries)
Transmission:
-Gen 2 6R80 Transmission
-GPZ Frictions and PBH Steels
-Modified Center Support
-Billet 300M Intermediate Shaft
-Billet 300M Forward Shaft
-Billet Forward Planetary
-Gen 3 Billet One Way Low Reverse Clutch
-Upgraded Pump Bearings
-Superior STL009 Sure-Cool Cooler Flow Control Valve
B&M 7 Qt. Transmission Pan
-Lokar Shifter (Future: Modified for Quick Reverse)
-Gen2 Quick 6 Controller with Remote OLED Display
Transfer Case:
-Atlas Pro 3.0 Transfer Case (Clocked Horizontal)
-Long Input Shaft
-Short Tailhousing with 300M Output Shaft
-1300 Series Flange Front and Rear
-JB Custom Fabrication Twin Stick Cable Shifter
JE Reel 1410 CV Canyon Crawler Driveshafts
Current Front Axle:
-Dana 44
-Disc Brakes
4.88 Gears
Chromoly Shafts
-Warn Premium Manual Hubs
Future Front Axle (Stretched):
Spidertrax 609 4” 4130 Chromoly (69.25” Wide)
Gearworks HP10 3rd Member (3.812” Case)
5.14 US Gear Shot Peened, REM Polished 10” 9310 Ring and Pinion
ARB RD249CE Competition Air Locker
Tubeworks Duplx Pinion Support
Billet 1480 Drive Shaft Yoke
WFO High Pinion Diff Guard
40 Spline Gun Drilled Big Bell RCV Shafts
Stub Shafts Splined to Direct-Fit Super-60 Unit Bearings
8 on 6-1/2” Bolt Pattern
Reid Racing Super Kingpin Knuckles
Artec Ram Mount
Artec Upper Truss
Current Rear Axle:
-WH Super 9 Housing (large bearing billet ends, 3"x0.250" tubes)
-Weld-On 3/16" Center Section Skid Plate
35 Spline 1541-H Alloy Axles
Timken SET20 Tapered Roller Bearings
-WH Wrap Trap
Third Member - 35 Spline ARB, Yukon 4.86 Gears, 3.250 Nodular Iron Dropout, 6061 Daytona Pinion Support
Stretched 1.25"
Future Rear Axle (Stretched):
14 Bolt
5.13 Gears
Billet 1480 Yoke
40 Spline Gun Drilled 300M Shafts
Super-60 Unit Bearings
8 on 6-1/2” Bolt Pattern
Future Steering:
-PSC High-Flow CBR Power Steering Pump
PSC 6061T6 Aluminum Remote Reservoir (with Radial Dynamics Cap and PSC Anti-Splash Valve?); or Radial Dynamics Remote Reservoir
PSC Hydraulic Assist
4x4x2 Power Steering Conversion
Busted Knuckle 7075-T6 Aluminum Drag Link and Tie Rod (Not RPM Steering; Rock Krawler? Busted Knuckle?)
-Ididit Tilt Column Black Powder Coated
-WH Custom Lower Steering Shaft
-WH Mark 9 GT Black Steering Wheel with Leather Wrap
Brakes:
-Wild Horses MOAB Hydroboost System
-Wilwood Master Cylinder
Wilwood or Camburg Cutting Brake (Future)
Wilwood 6 Piston Disc Front and Rear (Future)
Wilwood Electric Parking Brake (Future)
-Disc Front and Rear (Current)
Fluids / Cooling:
-Ron Davis Radiator
-SPAL 19” Brushless Fan, IP68
-Lingenfelter Fan Controller
-Derale Fanned Transmission Cooler
Custom Peterson 3 Gal. Dry Sump Tank
-Peterson Vacuum Regulator
-Peterson Pop-Off Valve
Setrab Fanned ProLine Oil Cooler with Susa Temperature Regulator
Clear View Filtration?
Oil Catch Can
Power Steering Fluid Cooler
PSC RV00 Vented Catch Cans with Rollover Valves (ARA1?)
-M1A1 Stainless Steel Fuel Tank
Discriminator Valve (Gasoline Evap System)
Vapor Trapper
Exhaust:
304 SS Ceramic Headers (3/8” Flange, 2” Primaries, 3” Collectors)
Borla ProXS 304 Stainless Steel Mufflers
3” 304 SS Exhaust
Exhaust Cutouts, Vacuum-Actuated (QTP?)
Suspension:
4-Link Front with Trac Bar and 16” King Coilovers 2.5 with SDi E-CLIK Remote Reservoirs
Double Triangulated 4-Link Rear with 16” King Coilovers 2.5 with SDi E-CLIK Remote Reservoirs
Busted Knuckle 7075-T6 Aluminum Link Bars
-2” Body Lift
Spidertrax Sway Bars (7075-T6 Arms, 300M Shafts)
Tires and Wheels:
37x12.50-17LT Mickey Thompson Baja Boss M/T (Future: 40x13.50-17LT)
17”x9” Baja Built Outlaw Forged Aluminum Beadlock Wheels, 8 on 6.5”
Exterior:
Metallic Pearl Blue Paint
Custom Full Roll Cage (Behind Dash)
Custom Prerunner Bumpers
Custom Sliders (Trimmed Rocker Panels)
Aluminum Skid Plates with UHMW
-Heavy Duty Wipers
-HID Projectors Halo Black Series Switchback Headlights
-Alice Turn Signal Mod
Warn Suckdown Winch
Rear Warn Winch
-Rear Quarter Panel Guards
-Upper Quarter Panel Guards
-SS Quick Remove Door Hinges
Door Checks
Optional Tube Doors
Hyperformance Tough Windshield
-Black Diamond Rampage Soft Top
Mike’s Metal Worx Wing Vent Window Delete
Extended Wheel Wells
Baja Designs Lights
Tailgate Assist
CJ7 Side Mirrors
Interior:
-Black Leather Corbeau Baja XRS Suspension Seats with Heaters and Lumbar Support (Future: Perforated Full Grain Brown Leather with Seat Coolers)
-Black Leather Corbeau 40” Baja Bench with Head Rests & Heater (Future: Perforated Full Grain Brown Leather with Seat Coolers)
Retractable Seat Belts (Future: Optional 5-Point Harnesses Front & 4-Point Harnesses Rear)
-BC Broncos Console
Fuel Pump Access Panel
-Rosen Aircraft Sun Visors
Electronics:
-Painless Performance Wiring Harness
-Custom Dakota Digital HDX-2014 Gauges
Dakota Digital Cruise Control
-Dakota Digital GPS with Remote Antenna and Ambient Air Temperature
-Vintage Air A/C Front and Rear
-Dakota Digital Climate Control
-iPad Mini 6 Dash
Digital Signal Processor
Backup Camera
-Dual Switch Pros SP-9100
Custom Digital Guard Dawg Keyless System
Speakers (JL Audio C2-650X?)
Two 12” Subwoofers
CB Radio
GMRS Radio
110V Inverter
-Heavy-Duty Synchronized Electric Wipers
ARB On-Board Twin High Performance Air Compressor
-Power Locks and Windows
Other Equipment:
AGM Jack
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