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Old 02-26-2017, 10:18 AM   #1
CJ
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Default The $1,400 Bronco Project

Here we go again.



Hopefully this turns out better than the $4,000 Jeep TJ Project.
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Old 02-26-2017, 12:01 PM   #2
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Oh really?

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Old 02-26-2017, 12:10 PM   #3
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SAS swap or what?
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Old 02-26-2017, 07:46 PM   #4
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Sweet look forward to the updates.
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Old 02-26-2017, 07:55 PM   #5
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The good:
351w, 104k miles, 4x4, decent interior, new A/C everything, new cooling system, new suspension, runs great

The bad:
She's from Minnesota and full of rust, shifts hard, smoke in interior followed by gauge cluster death, driveline vibration

95% sure cluster will solve shifting issues, most likely VSS related. It's defaulted to TPS for shifting. Driveline vibration feels like driveshaft to me, not worried either way.

The real problem is the rust. The previous owner replaced both quarters and fenders. First and foremost I need to stop it. I'm thinking of taking it to have it blasted off and then painting everything on the under carriage, and assessing where I go from there. Once that's done I need to realign the quarter panels and fenders, weld them in the proper location (currently alignment is lacking), and then repaint the truck. Not sure if I'll base/clear it or just hit it with a single stage satin black or something.

Once that's out of the way I'm going to turn this thing into an offroad juggernaut.
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Old 03-03-2017, 06:59 PM   #6
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Fixed the cluster, transmission/shifting issues, etc. Vibration is pinion angle, I'm almost certain.

Rust isn't as bad as I had initially thought. I'll be tacking the undercarriage and frame over the next few weekends. Once that's done I should have it 100% and I'll be priming it with some 2k epoxy. Once I get it all leveled out (honestly it's super straight now) I will shoot some single stage satin gunmetal grey.

Something like this:




I'm also in the market for a set of one ton axles. I'm looking for Dana 60's out of an F250/350 - front and rear.
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Old 03-05-2017, 09:16 AM   #7
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Quote:
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just sayin' brah. If you're going to make it a serious trail rig with d60's or 1 ton axles than it makes sense, because all the factory stuff would have to go regardless. But if it's going to be a budget build it just seems like (here it comes) a factory wrangler would end up being the same amount of money once you get live axles under there and everything fabbed up.
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Old 03-05-2017, 09:36 AM   #8
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Rusty trucks are perfect for cutting up for a CORR style truck. Almost got one last summer. Good luck on the build. What's gonna happen w engine mods?
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Old 03-06-2017, 08:11 PM   #9
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��
What the fuck was that brah? Fox +5k reversal?
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Old 03-07-2017, 08:28 AM   #10
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This thing is going to be awesome when you paint it and it morphs into a first gen bronco, I can't wait lol.
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Old 03-07-2017, 09:20 AM   #11
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What the fuck was that brah? Fox +5k reversal?
just thought I would give you some advise i got once.
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Old 03-07-2017, 07:11 PM   #12
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just thought I would give you some advise i got once.
Alright, that's what I thought, haha. In certain situations I would agree. If you're broke an XJ, if you want a very capable daily a TJ, but if you intend to make a dedicated trail rig with one ton axles, anything under 4,000lbs is pretty much on level ground. Honestly, putting tons on a TJ or JK is a major pain in the ass. I look forward to an extremely easy conversion on this Bronco, which is why I bought it (and it was about four times cheaper).
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Old 03-08-2017, 06:57 AM   #13
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You gonna do 05+ axles?
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Old 03-08-2017, 08:56 AM   #14
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You gonna do 05+ axles?
I believe the newer super duty trucks have Dana 50 front axles, don't they? I was looking for Dana 60 front/rear from a 92-96 f250/350, but I will admit I don't have extremely intricate knowledge of the nuances between the years.
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Old 03-08-2017, 08:57 AM   #15
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This thing is going to be awesome when you paint it and it morphs into a first gen bronco, I can't wait lol.
They're doing amazing things with paint these days.
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Old 03-08-2017, 09:51 AM   #16
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Yeah, I'm not sharp on the 50/60 years but guys are swapping the 05+ front axles in and end up with a better ride and turn radius. I'll probably be helping a buddy do this swap in his 04 Superduty sometime soon.

http://www.fullsizebronco.com/#/topi...ge=3&_k=w72g4v
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Old 03-08-2017, 10:39 AM   #17
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I believe the Dana 50's use a Dana 44 ring. I really don't know that much about them, but the consensus is the D60's are better in just about every way. If I'm going through the trouble I might as well go big or go home I guess, unless I find a super cheap pair. Are the 05+ D60's are sought after because of the ride/turn radius only?
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Old 03-08-2017, 05:35 PM   #18
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The Dana 50 does use the 44 differential.

I believe all 05+ are going to have the 35 spline inner and out shafts but not all will have the Super 60 upgrades.

I had only just begun reading about the later 60s before picking up our chassis with the older style and abandoning research into them.

Also the rear is going to be a 10.5 Sterling in the F250/350.
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Old 03-09-2017, 09:11 AM   #19
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Plenty to read here. http://www.pirate4x4.com/forum/gener...a-60-axle.html
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Old 03-10-2017, 07:03 PM   #20
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And so it begins. Didn't seem too bad at first, then I switched to my air chisel and punched through a body mount. So now I'm fabbing new body mounts. A little bit of sheet metal work and cleaning and then I'll shoot it with chassis saver.



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