My Ford Bronco Build Thread

[TKSC01]

Weekend Overview....Design Change and 1 Ton install.

So...onward we go...this weekend I had a chance to set the Sterling in place. No final by any means but it is in for now. I will soon pull it back out and set the pinion angle and clean it up, weld it all in and paint. Lot still to be done to the rear but I wanted it off the jack stands. I prefer to have te entire truck on jack stands as little as possible. I also finally picked the "TAN" color that I wanted to accent the truck with. I started with the painting, again not done by anymeans but a start and wanted to share.

 

[TKSC01]

Oh and by the way....

Check out this pick of the Ballistic Fabrication Leaf spring Plates...I have never been close to a Battleship...but these things look like they belong on one ULTRA STOUT!!!!!!
The spring perches are from Ballistic as well and they are a PERFECT FIT! I have yet to be even remotely unsatisfied with the quality of anything from Ballistic!!

 

[TKSC01]

Rear Tire Carrier

I started working out the tire carrier situation, it will fold down in the rear instead of swing down. If I work it out right I may be able to use it as a table in the woods. Here are some pics. Oh and I mounted the rear tires and rims.

 

[78Bronco]

I would call James Duff and buy a set of there extended radius arms which are the same as the Cage units. There are a few reasons to keep the radius arms and coils.

First, it's pretty much a bolt in job. You will need to cut the spring perches off the D60 and weld on the axle wedges.

Second, It allows you great flexibility in positioning the axle further forward to clear you really wide axle/wheel/tire combo. In order to get decent ride out of leaf springs they need to be relatively long, but you only have so much frame on the front side of the axle to mount the springs. Next thing you know you have to build a big f'n cross member to hang off the front of the frame to mount the leafs to.

Third, ability to try different spring rates is a LOT easier and cheaper with coil springs. I have 300 lb/in deaver coils in my 78 now but if I want to go to a heavier coil I switch to a BDS @ 350 lbs/in. It takes about ten minutes per side to swap out. Now imagine you want to adjust the spring rate of your leaf packs.

Fourth, it is a bronco not a blazer:coffeedrink:

Fifth and final, Coil springs are far more efficient and aren't flawed by friction that hinders the responsiveness of the leaf spring. Therefore, in sharp washboard a leaf spring bronco will really be BUCKING but a coil spring bronco will be big PIMPIN.

 

[bftank]

a radius arm coil sprung 60 is not a bad idea and something i would like to see.

 

[78Bronco]

a radius arm coil sprung 60 is not a bad idea and something i would like to see.

Been done many times...here is some information.

http://2bigbroncos.net/technical/D60/

http://www.4wheeloffroad.com/techar...2002_chevy_2500_solid_axle_swap/photo_08.html

http://solidaxlesuspension.com/techarticles.html

 

[TKSC01]

Thanks for your posts, and I may have mentioned that I am going leaf springs prior but I am no longer going that route. I am using the coil springs that are on the truck and using the spring holders from Ballistic Fab. I will then measure the distance between the brackets and the frame mnount an make my own radius arms for way less then the cage productas. I already got quotes on them and although great, expensive.

 

[RU55ELL]

I can't wait to see it after the SAS!

 

[shfd739]

Nice looking Broncos. Your build is interesting and I'll have to keep watching it. I've always loved these trucks and have considered trading/selling my '97 Land Cruiser for one.

 

[78Bronco]

This is why I avoid progressive rate coils. The soft portion of the spring rate collapses easily and gets coil bound...pretty much useless IMO

 

[RU55ELL]

Are the perches built too narrow?

 

[TKSC01]

I'm not sure I understnd the question.

 

[Scoop]

Wow - lots of progress since I last checked. Looking good. Glad to see you're using the bumper as is to hold the tire carrier - that's exactly what was intended in the design my son did.

BTW, Congrats on the new baby girl!

 

[RU55ELL]

I'm not sure I understnd the question.

It kinda looks like the spring is contacting the sides of the perch before it compresses solid in the upper part.

 

[59bisquik]

Great lookin Bronco! I saw that you were talking about radius arms on your D60. Cut up your stock set and make some, much cheaper than Cage or Duff. Here are the ones on my D44