1984 Ford Bronco Project

[Lanlubber In Remembrance]

A little more done on the front suspension. I finished welding up the shock hoops.

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I put the axle beams in place and put the coil-overs in place. It is fitting pretty nicely.

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I still have to let the nitrogen out and remove a spring so I can make sure everything clears before I weld the lower mounts on to the axle beams.

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The new radius arms a just a slight step up.

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Completely compressed.

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And fully extended. both sides are check and now to weld the lower mounts on the axle beams.

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Comparison of the original size front shocks to the new coil-overs.

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My ocd kicked in again and I had to cap the ends of the lower tubes on the upper shock mounts. Not much practical need but I looks a lot more finished this way.

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Now, I just need some more clean up and prep to add a few more finishing touches to the front suspension.

Did you build all that yourself or was it a kit. Looks really nice. I agree with you on capping the open end tubing. Will you keep the collapsible front frame rail section or cut them off and extend your from frame rails ? Will you be building your own winch bumper ? This rig will be a tank when your finished !! :-)

 

[Dakota Houligans]

As much as I'd like to claim I built it. It is a kit. I'm not sure on the front of the frame yet. I've built a winch bumper previously for my other bronco. But it had the straight front frame so not sure if the mount could be easily reconfigured. But most likely I'll have to decide between building a new bumper or changing the front of the frame.

 

[M Rose]

As much as I'd like to claim I built it. It is a kit. I'm not sure on the front of the frame yet. I've built a winch bumper previously for my other bronco. But it had the straight front frame so not sure if the mount could be easily reconfigured. But most likely I'll have to decide between building a new bumper or changing the front of the frame.

While the front frames are similar, the pre-crumple zone is wider. I had to modify the “ShadowFax” winch plans to stretch the winch plate... without going back and looking at your old bumper, you might get by with two 1/4” spacers.

 

[Lanlubber In Remembrance]

As much as I'd like to claim I built it. It is a kit. I'm not sure on the front of the frame yet. I've built a winch bumper previously for my other bronco. But it had the straight front frame so not sure if the mount could be easily reconfigured. But most likely I'll have to decide between building a new bumper or changing the front of the frame.

No shame in buying prefab components IMO.
The only reason I asked is because I've not seen a shock mount hoop with that configuration. Usually they are horse shoe shaped and tied into the roll bar cage with a double flange connection similar to your cross bar connection. I'm comparing your layout to an off road pre runner configuration that I've seen in some off-road magazines. I'm pretty sure they do it their way because they are built for racing, not rock crawling.
Great job as I see it ! Onward :-)

 

[Dakota Houligans]

While the front frames are similar, the pre-crumple zone is wider. I had to modify the “ShadowFax” winch plans to stretch the winch plate... without going back and looking at your old bumper, you might get by with two 1/4” spacers.

I did a quick tape measure check when I first took it apart and remember it being pretty close. May just have to adjust mounts.

 

[Dakota Houligans]

No shame in buying prefab components IMO.
The only reason I asked is because I've not seen a shock mount hoop with that configuration. Usually they are horse shoe shaped and tied into the roll bar cage with a double flange connection similar to your cross bar connection. I'm comparing your layout to an off road pre runner configuration that I've seen in some off-road magazines. I'm pretty sure they do it their way because they are built for racing, not rock crawling.
Great job as I see it ! Onward :-)

I've debated on tieing it to the main cage. Just not sure its necessary for my use. But on the other hand I may do something dumb when left unsupervised...

 

[M Rose]

I did a quick tape measure check when I first took it apart and remember it being pretty close. May just have to adjust mounts.

There is less than 1/2 difference with the pre 1991 being wider, so adjustments going from older to newer are a lot easier... 3/8” - 1/4” spacers is all the would be needed to shim the bumper back up.

 

[M Rose]

Now it was time to return it to the original color. First I scrubbed it all with a special soap that has some grit in it and helps to remove a leftover junk that would mess up the new coating. Then you spray it down with a wax and grease remover at wipe it down until clean. Right before you spray the color you spray down an adhesion promoter that is used wet on wet. The color has to go on while the adhesion promoter is still wet so it will melt into the plastic.

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After the first light coat. of SEM Color Coat.

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After 3 lightish coats it actually looked pretty decent.

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This is how it looked before.

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And of course a sort of final assembly picture to see about what it is like back together.



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Turned out pretty good. I still have several panels and trim pieces to fit around the cage and then probably do the same refinishing to them.

What color did you use? A member on the FSB forum is looking for the red to redo his dash and plastic trim pieces.

 

[Dakota Houligans]

What color did you use? A member on the FSB forum is looking for the red to redo his dash and plastic trim pieces.

It's pretty close.

 

[M Rose]

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It's pretty close.

Thank you, I’ll pass it along.

 

[Dakota Houligans]

Limit strap mounts and new mounting for the front brake hoses are welded on. I still need to drill out the hole on the upper mount but they are in place.

 

[Dakota Houligans]

Also managed to get some work done on the rear brakes. Tore the drums off to make room for the new brackets and disk brakes.



The rotors are the same as the front ones on the bronco/F-150



Caliper is off a early 80's chevy 3/4 ton. So replacement parts are easily sourced.



I'll have to double check after everything is fully welded but it's pretty tight with the factory 15 inch wheels. But may be doable if I want.



Brackets are all welded in. Still need to replace outer seals and bearings and press in some wheel studs. But that will have to wait.

 

[Dakota Houligans]

The original wedge blocks that set the pinion angle were cracked. So picked up some replacements spring perches so I can set the pinion angle correctly and gives the springs a little bigger mounting surface.






Old mount cut off and axle cleaned up. New one test fitted.



And back in place. I'll wait until the rest of the drive train is in place so I can correctly set the pinion angle then I will weld them in.



I still need to add the tabs to hold the flexible brake lines that go to the calipers. I also need to test fit the front clip so I can see if I like the way the bumper fits or if it can be easily modified to fit.

 

[Overland California]

Looking good!

 

[M Rose]

It’s coming along great Dakota... I love the new spring perches... now you are making it very hard not to tear deeper into mine.

 

[Dakota Houligans]

Thanks. Progress has been slow lately. Life likes to get in the way. It would probably go a little faster if I didn't overthink some things.

 

[M Rose]

Thanks. Progress has been slow lately. Life likes to get in the way. It would probably go a little faster if I didn't overthink some things.

Overthinking leads to over engineering... over engineering leads to over built.... over built leads to awesome hardcore rig...

 

[Dakota Houligans]

Time to start getting the axle beams and radius arms prepped and painted.



Cleaned up and mostly sanded axle beams.





Sanded cleaned and ready for primer and paint.



2 coats of epoxy primer and 3 coats of semi gloss industrial paint.



Radius arms prepped for primer and paint.





Turned out pretty decent. Just realized when I look at these pictures that I forgot to remove and paint the axle pivot brackets... Oops. Oh well there is plenty more stuff to paint.

 

[Overland California]

You cut and turn those beams yourself? How about the radius arms?

 

[Dakota Houligans]

You cut and turn those beams yourself? How about the radius arms?

Nope. Just added the tabs for the coilovers and limit straps.