Bronco Blitz. Desert Thrashers 1 ton build up thread.

[Desert Thrasher]

It's been awhile since I've updated this build thread. I just fabricated a new transfercase crossmember. The first one I built worked great. However after some hard abuse, lots of using it as a pivot point on large boulders and big concrete tubes, it had actually bent upwards and was touching the Atlas. I knew I had to remove it and build another. So instead of 1.5"x.120 wall square tube, I used 1.5"x.250 wall round DOM.
Also this time instead of going flat across the frame I angled it up just after the tcase. Hopefully this will help with ground clearance some. I wish I had a 1.5" die for my tube bender but they are expensive and I only have a 1 3/4". So it is built out of 2 pcs welded together, still better than the 3 pcs from the first one though. I still need to attach it to the TMR tcase support, but that should be easy enough. This time I really need to build a skid plate between the transmission and tcase crossmembers. That probably would have saved the first one by spreading the load between the two crossmembers. Anyway here's some pics.

 

[5001craig]

What a great post!

I'm needing to build a crossmember for my TMR bracket that should arrive soon. Thanks for posting your pics and I look forward to seeing how you tie the TMR bracket in.

Craig

 

[Desert Thrasher]

Well my crossmember didn't last long. I was worried about it being 2 pcs welded together instead of a solid pc with a bend. And after some rough crawling on John Bull in Big Bear the weld split at the top. So now I'm going to make it again, but this time I will have a bend in it not welded. Luckily I know someone with size die I need for my bender now. And I will also actually finish it this time and make the skid plate between the transmission and tcase crossmembers. Anyways here's some fun pics from John Bull.

 

[Desert Thrasher]

Ok finally got around to building the atlas crossmember (again). I went back to my original design this time. 1 1/2" square tube. I added some gussets where the angles are to help prevent bending and I actually made a skidplate that goes between the transmission and tcase crossmembers. I think it will definitely help spread the load and impacts between the two crossmembers. Next I want to either get some button head bolts or weld the bolts to the skidplate to make it easier to remove/install. Also need to attach the atlas support mount into the crossmember. Here's some progress pics.

 

[Yeller]

I usually use counter sunk bolts so it's completely flat. That also makes them replaceable if for some reason you need to.

 

[Desert Thrasher]

That's a good idea, I'll see if I can find some.

 

[Desert Thrasher]

Finished the crossmember today! Got the TMR atlas support mount added to it and all painted with Rustoleum hammered black. As for the skid plate, decided to weld the bolts in and smooth them out with a grinder. I'll get pics of it all together maybe tomorrow or Monday.

 

[garberz]

Will I be able to see the in Calico?

Mark

 

[Desert Thrasher]

I'd like to make the Calico run. Depends on funds. Christmas wiped me out lol. It's so close to my annual New Years Truckhaven run that it's hard to make another trip back to back.

 

[Desert Thrasher]

Here is the new crossmember/skidplate/atlas support mount all bolted up. I like how it turned out. Should be plenty strong.

 

[Desert Thrasher]

The new crossmember held up just fine! Even when all of the weight of the Bronco is on it and pivoting. Just wish it didn't hang so low. Oh well maybe I'll make another one later that won't be so low.
Now the bad news. My Ruff Stuff Trac bar bracket didn't survive. I noticed awhile ago that one of the legs that go up the side of the frame had a crack, so I ground it down and rewelded it. Well now it's tore the side of the frame out and then I noticed the other leg has a split in it right where the leg goes up and the back piece stops. Bad design in the bracket I believe. So now I'm going to cut it all off and reinforce the frame then plate it with 1/4" and get this new bracket from TMR Customs. It's a lot beefier and fully gusseted. It's got the same drop as the other but a wider offset so I will have to make a longer Trac bar, which is actually a good thing. I'm just glad I caught it now before it completely failed while driving it!

 

[Desert Thrasher]

Well after waiting almost 3 weeks I finally got my bracket from TMR Customs. They were back ordered and behind in production so they had one of their vendors who had it in stock ship it to me. Great customer service, just sucks I had to wait so long. I was about to make my own, but I didn't have time. So I plated the frame with 1/4" plate after patching the hole I cut out from the old track bar tearing and got it all ready. Anyway I just got it finished today. It definitely looks beefy now! And it made my track bar almost 2 inches longer without changing the geometry. I also filled the old steering box holes up to clean up the frame.

 

[Desert Thrasher]

Been awhile since I updated this thread. Been enjoying the Bronco.
So my side step bars I built a long time ago that I never really liked much finally were in need of replacing.
After cutting off the old ones it was time to break out the tube bender. I forgot how much of a workout bending tube is! I need to get the air/hydraulic system!
So I measured wrong somehow and my bars came out about 5" shorter than I was looking for. So I took the opportunity to improve on my mistake. I cut the 1 3/4" bar in half and sleeved it with 1 1/2" tube, basically doubling the wall thickness. I extended them the 5" to a total length of 42" which spans the door opening.
Next thing I learned was that it would have been much easier to add the extra support legs BEFORE I welded the step bars to the rockski! Oh well lesson learned.

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[Desert Thrasher]

A few pics from my Rubicon trip.

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[74 Bronco Billy]

Awesome pics, the Rubicon is my backyard. I wish mine was done, I'd have gone too.

 

[Bitch'nBronco]

Awesome build, love those Harley headlights! I may have to copy those on my Bronco

 

[Desert Thrasher]

I let this thread go way too long without updating, sorry.
So after my Rubicon trip over a year ago I’ve still been upgrading the Bronco.
First thing was new brakes for the rear. After pricing everything out, it was actually very affordable to swap to rear Discs. I used brackets from Ruff Stuff and locally sourced everything else. On Ruff Stuffs website they mention some Sterling rear axles need a spacer for the caliper brackets to work. Of course mine happened to be one. But only the passenger side. So I fabbed one up and everything went together just fine.
I researched master cylinders for awhile and found a 1976 F350 with a 7.5l engine had a 1.250” bore so I bought one and removed the residual pressure valve from the port so my disc brakes would work correctly.
The Brakes are amazing now!

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[Desert Thrasher]

Up next was hydro assist steering. I sent my 4x4x2 box off to West Texas Offroad for a rebuild and to be tapped for hydro fittings. I also ordered their ram assist kit.
While that was being done I ordered some offset Heim joints from Barnes 4wd. These are cool, they allowed me to gain clearance of my tierod and front diff cover as well as full lock to lock steering.
After mocking up my rebuilt box I quickly noticed the straight fittings that came with it wouldn’t work for me. So I switched to 90deg fittings out of the box which worked great.
To install the ram I utilized the lowest hole on my Trac bar bracket and built a double shear mount for it. Then welded the included tabs to my tierod. Next I purged all the atf from the WH Saginaw pump and lines and refilled with actual power steering fluid. Hyrdo assist is awesome, steering is effortless even when fully locked.

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[Desert Thrasher]

Finally it was time to get some 40s and beadlocks. I really wanted to get some Pitbull Rockers, but I knew as often as I drive the Bronco they just would not last and I cannot afford new 40” tires every year or two. So I eventually decided on more Coopers. I liked them in the 37s so I was confident that the 40s would be even better. They are Cooper Discoverer STT Pros in 40x13.5-17.
For wheels I went with KMC Machete Crawl beadlocks 17x9s. I love the looks of these wheels! So damn sexy!

With the help of my Brother (he’s the one in overalls) we got them mounted up in about 4 hours. I even got my daughter to help a little, proud Dad right here!
I knew they were not going to just fit and clear everything so I did a lot of test fitting and cutting. Unfortunately I had to cut out those nice inner fender tubs I had finished previously. Sucks but worth it. I still need to fabricate some new ones again. But the 40” Beasts clear! And with less backspace than the h2 wheels I got the badass stance I was wanting.

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[JeffG]

Awesome. I agree. I like the looks of those KMC Machete wheels!!