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Money Pit - Phase III

jlylec

Sr. Member
Joined
Jul 5, 2012
Messages
891
Looks tough as hell! You gonna paint it? It would look awesome just in rattle can matte black I bet.
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
I'll paint it after I'm done with the majority of the build- matte black would really look mean, but I'm thinking of keeping the current color. Saves me lots of time taping off the inside as it's still vibrant as it came. I've got to pull the trans and rebuild it as its a complete pile of shit after having to mix and match two transmissions on my trailer two years ago. 3rd is nearly impossible to get into and first/reverse pops out and is painfully loud. I may pull the engine at the same time for some more love'n - which will give me even more room to paint the firewall and such.

I swapped a master cylinder and my original rubber flex lines are about toast - one broke and I was able to flare it with what was left, but that's the last of it. I couldn't get the line off the distribution block with a line wrench either - so I've got a feeling I'm going to have to replace all of it one of these days... It's pretty much the only stock stuff left to the drivetrain at this point-

This will be the last run I go on without a roll cage - I've wheeled WAY too long without one and now is the time with these big tires and probably more horsepower down the line (again).

Today I'm picking out my wedding tuxedo and then I hope to take this out for the first time. I need to secure some help to bleed brakes -
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Well I still don't have help to bleed brakes, but I've got more brakes than I wheeled with for the past two events, so I got a little work done today.

I don't fit nicely on my trailer anymore - figures. I may screw some wood down on the insides of the rear wheel wells so I can center it up on the trailer.
20140720_131504_zpsc86fbkqp.jpg
20140720_131522_zpszden8f3t.jpg


Of course that meant I had something to climb on -
20140720_134001_zpsjmlg2yoi.jpg

20140720_133939_zpsijjccg4i.jpg

I caught the fender on that one - which is why I was doing this in the first place. Of course I worried about the rear hitting and I actually cleared that fine and caught the front.

So with the tire sitting about here-
20140720_133514_zpsrfymfkj0.jpg

20140720_133601_zps9u6styxs.jpg

20140720_133524_zpswytcuhca.jpg

the leaf spring looks like this-
20140720_133014_zps6fvdbwq6.jpg


I've actually been using a bit more up-travel that this the entire time, but I've been abusing the hell out of the leaf springs. I don't think you are supposed to invert them like that.
I often did this to them with my 37's-
DSCI0041.jpg


I'm going to do some trimming around the rear wheel wells (obviously) and while it was twisted up I did some measuring for later.

At what I'm going to now call full bump I've got 3" from the leaf spring plate to the frame.
20140720_132839_zpsaaan9ld3.jpg

I'm going to weld either some tubing or angle iron to the side of the frame and mount the poly bumps so the make contact with that beefy Ruff Stuff leaf spring plate.

Now for shocks - I have not had shock on the rear of this for quite some time, I'm talking years :eek:

Looks like I've got plenty of room off the original leaf spring perch for the lower mount and I'm going to tie them into the cage in the wheel well.
20140720_135040_zpscoac6aso.jpg


James Duff 70/30 14" travel shocks on the way with a two pair of Ruff Stuff flat mount shock brackets. The shocks are ~ 20.5" compressed which is shorter than my available space and the are 35.5" extended. I'm thinking I'll lower the top mount a little bit to get even more down travel out of the shocks - probably don't need it, but I'd rather not use them as a limiting device.
8120-2.jpg


fltbrkt.jpg


I'm hoping everything fits nicely in there - the full width axle and offset wheels sure leave me a bit of room.

Wow I sure go through brake pads WAY fast - like multiple sets a year. I'll try some better pads- probably semi-metallic?
20140720_135306_zpsctkxnxbz.jpg


Here the Bronco sits next to my brother's Blazer on 40's
20140720_140428_zpse7ijwymk.jpg


I love how the wheels and tires turned out-
20140720_140451_zpskodtaiju.jpg

20140720_140521_zpsy78q7ou3.jpg

20140720_140539_zpsckhhpgeu.jpg


FOA is graciously going to shorten my bump-stops for me, but I won't have those in time for next weekend. I've got to get back over to my pop's place to plasma cut some more sheet metal, luckily not as much as I thought.

More to come-
 

Mountain Ram

Contributor
Recovering Masshole
Joined
May 8, 2011
Messages
3,387
Loc.
Abingdon, VA
Looks good!

Some day I will move to the SXs as they are narrower than my 44" TSLs, but your rig does not look a whole lot more narrow than mine does. I am running 2 3/4" BS 15x10 wheels.
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Did some brake work tonight - my lines ended up not sealing and I couldn't flare it anymore, so luckily I had a set of stainless lines for my other project just sitting. I had my fiance help me bleed brakes but it still was spongy. I get some fancy Wagner ceramic pads for the rear (seriously the nicest I've gotten, nice paint and great packaging) as they have a lifetime warranty. We shall test that - lol.

I took the calipers off WITH the wheels on and clamped the piston in all the way and gravity bled them. I cleaned everything up and put everything together in the wheel well above the tire and stuck it back together. Braking vastly improved, still one pump to get the pedal firm at the top, about as good as I'm willing to get it for a trail machine. It's clear the rears do most of the work.

I'm not happy with my initial steering feel and I'm going to lift the reservoir up on the pump to try and get some more flow out of it. Tomorrow I hope to plasma cut out the fenders and possibly weld on my bump stop mounts. I can weld up my shock mounts with my 110 or the spool gun if I really need it... lol
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Took some more measurements for shocks - my initial plan is not going to work as the roll cage isn't as sturdy as I thought. I have a pair of shocks that are going to work fairly well off the stock mounting location -

I don't think the wrap bar is affecting articulation at all-
20140723_180927_zpshseerrgp.jpg
20140723_181722_zpss2bvab33.jpg


I swung over to my pop's place and plasma cut out my fenders and tested my light bar mount - it's overkill and the light is brighter than I imagined...
20140723_221400_zpshyjzwsvw.jpg
20140723_221351_zpsxkoiwct1.jpg


Tomorrow I'll mount shocks and bump stops - then I can worry about the little things. This weekend I'm going wheeling! ;D
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
I got my shocks and bumps done - went well, wheeling did not.

20140726_130526_zpsrct3czah.jpg


Came in on the strap - I got about 30 minutes in before something died with the throw out bearing/fork pivot point. I couldn't even get it to work on the trail - included lots of starting in gear and front digs to get back to camp. I'm DONE with NP435's - I want another C4.

We did drink 17 jars of moonshine though - that was fun!

It looks like I'll rebuild another NP435 and put a hydro clutch on it - I've got an aluminum bell setup for it, so I'll give that a try. Too much cash to go back to a C4 at the moment.
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Doing some digging I think I've been running the wrong clutch fork that I got with my trans parts for some time. JBG has one on the way - I'm pulling the transmission out this week so I can rebuild it from my 4wd NP435 and put it back in for one last ride.

My recent purchase-
20140802_223039_zps4ipx0igg.jpg


Obviously not going to use the D20 stuff, but the C4 is going in this winter - ;D

I bought shocks for the rear of the Bronco but they didn't turn out working like I had wanted, so I put them on the front. I'm excited as I've been thinking the Cage shocks I've had on since the original build have always felt a bit soft. Looks like I'll gain some down travel as well-
20140803_163616_zpsf5ianbwg.jpg

20140803_171841_zpsllvlk2bf.jpg
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Well I yanked out the terrible transmission tonight -

I like to take it with the transfer case - usually easier for me.
20140808_213851_zpsqvy0vogg.jpg


Well, there is problem #1 - the entire surface that supports the TOB broke off and turned into anti-seize all over the place.

So I go to pull the tcase off with the adapter and everything is going well, until the tranmission starts coming out with it...
20140808_222056_zpsdcmegkp9.jpg


I ended up having to take the 6 nuts off the other side and remove the tcase from the adapter, then everything came apart nicely. So much for not making a mess!

Muahaha - maybe that is where the angry noises are coming from?
20140808_223737_zpspmw5lntx.jpg


I drained the fluid out and cleaned up my mess and called it a night. I wanted to try and give a sense of how bright the 50" 10w light bar is, I think this does it some justice. This is only the light bar on the Bronco-

I'm about 50' from the garage at this point
20140808_235143_zpscglno119.jpg


Around 100'
20140808_235202_zpsfkzu0rga.jpg


I can't wait to check it out while driving around, should be great for plowing!
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Well today I took a break and decided I was going to win and get these goddamn door hinge pins out... I ended up having to grind my own attachment for my air hammer, heat the hinge top and bottom cherry red and give it hell. They came out-

20140809_160735_zpsnlckgkh5.jpg
20140809_160708_zpspggevdvj.jpg


I can't wait to see how they are for driving around - on to that...

Got my parts transmission out of the barn - starting this later.
20140809_173512_zps1ynfmypl.jpg
20140809_173520_zpsrcpxgmzo.jpg
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Ok, teardown took roughly five minutes- 1/2, 9/16, a gasket scraper, snap ring pliers and a hammer is all you need.


The input and output split in the middle and come out separately.

Remove the main shaft keeper tab and bearing cover and drive out reverse pin to remove the lower shaft. My reverse gear is hammered!

Time to clean this pig, the metal on the magnet is literally 3/8" thick!
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Ok, the rest of the rebuild -

Parts trans-
20140810_145720_zpsu3dtrnpt.jpg


Looks brand new! (its a rebuild with like 2K on it)
20140810_145935_zpsxxbhz9dc.jpg


Pulled the guts - output shafts side by side.
20140810_161914_zps66enpltr.jpg

20140810_161906_zpsnwwfrn62.jpg


Old on to the new-
20140810_162432_zpscauaynvj.jpg


Guts installed-
20140810_165509_zpsfy7fvtou.jpg


The junk box-
20140810_174838_zpsqkh9fmmr.jpg


Cleaned up the Atlas and swapped the front output out with my spare as the one I was running had a chipped corner.
20140810_183113_zpsl2ektaen.jpg


Tossed the housing on with gaskets and filled it up with fluid (whatever came in it, looks like 50w motor oil?)
20140810_190857_zpsvistkcbj.jpg
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
I got everything installed slowly over the week - life seemed to get into the way from time to time. This transmission is perfectly silent - shifts really crisp and totally changed the way I can use my gearing.

Clutch linkage ended up perfect with the new fork -
20140814_220031_zpsrofwrcxz.jpg


I grounded everything in my OBA setup to the frame to get the compressor to run better and played with my air pressures a little bit.


8psi up front and 3psi is the rear - after some aggressive driving I'm thinking I'm going to need at least 5spi out back to keep the tires from folding so much when lots of throttle is applied while turning the wheel :D

20140816_172156_zpskycb8t7r.jpg



I've been fighting an odd issue with the EFI - sometimes the motor will run rough and will not rev past 4500rpm. Check this video out - tach goes crazy.
http://youtu.be/j_QCjaaKw1o

Now if I start the Bronco with the key off and turn it on afterwards it runs sweet-
http://youtu.be/cpNfPRdqx7U

The key only turns on the tach and alternator - what gives?
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Well I got to try out my tires - they work awesome!
I'll embed later as I'm currently uploading - lots of video. I tried a new camera angle - what do you guys think of where I have it mounted? Some of the later videos I change the angle down and took off the waterproof door.
https://www.youtube.com/user/D3thM3tal/videos?view=0&sort=dd&shelf_id=1

I got really hard on the Bronco a few times and had some breakage - the joint broke both crosses off, pushed the clips lands off, shot parts all over the obstacle, put a giant dent in my floor and broke my extinguisher mount. The yolk was fine - NP205 parts FTW!
10641047_10203688413243766_5112501219677938317_n_zps0959e570.jpg


My front spare didn't end up fitting after all so I went home and grabbed some spares, cut down and made two replacements and headed back to the trail head- had to take out 2" with 5.5" lift and 1 tons...
20140823_174522_zpse058c9a9.jpg


After that I was nothing but throttle happy hill climbs and wheel stands. The Bronco went everywhere I pointed it- a lot of the lines I took were un-touched the entire weekend...

http://youtu.be/LxLZptVz2q0

http://youtu.be/71XGuHQdIyU

Made it home safe - nothing broken, just dirty
20140824_213136_zpsf8a912c1.jpg
 

68rockcrawler

Bronco Guru
Joined
Sep 18, 2006
Messages
1,417
Well I got to try out my tires - they work awesome!
I'll embed later as I'm currently uploading - lots of video. I tried a new camera angle - what do you guys think of where I have it mounted? Some of the later videos I change the angle down and took off the waterproof door.

Camera angle looks good. I haven't seen many videos shot from this angle, but it works really well. I'm surprised you didn't end up with mud globs on the camera!

Your engine sounds healthy!
 
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KyleQ

KyleQ

Bronco Guru
Joined
Apr 24, 2008
Messages
5,480
Thanks - it is kinda neat to get the driver's height perspective, I really need a screen on the camera so I can see where it is pointing.

Engine ran great all weekend - I really need to hook up a gas gauge, but I think I went through about 5 gallons for 2 days of wheeling.

The Duff shocks are AMAZING - made a giant different for ride quality and I've totally lost my wheel hop. My bumps in the rear works well, but they can be a little harsh at times - I may try and trim them a little bit. The tires never seemed to get close to the sheet metal and I actually lifted a tire for the first time on a climb.

I thought I had damaged my Atlas gearing as it was making an odd noise in the same spot from the rear output - swapped rear drive shafts (which felt smooth and tight on removal and inspection) and the noise went away. After I blow up my two spares I'm going to look at a 1350 or 1410 rear output to handle the abuse. Luckily I know a guy who makes forged yolks for these and he happened to use my Atlas for measurement as well :)
 
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