Project "Wilma" 1971 Bronco

[Justin]

Take anything home?

[landshark]

Just the stuff in my thread. I posted the above for hockeydad.

[hockeydad4-22]

Gents,

As of 3 days ago I was planning on building with stock bronco axles, upgrading them and that made perfect sense to me. New I am considering dana 60's? Already this has gotten out of hand.

remember, there is no plan for heavy duty, extreme wheelin in my future plans, and if I ever did, I can change the axles then.

The high pinion full width 44, and full width 9" will be more than enough of an upgrade. Might even talk about trussing them ala landsharks recent upgrade.
Besides, I already found them, 2 44's in fact. And all I am going to be out is $200 bones that I will attempt to make up by selling the extra once I swap out the parts I do not need.

I have not mentioned this before but I have a challenge that I can have this thing ready for under 5k. So I need to consider budget as well.

[Rox Crusher]

Gents,

As of 3 days ago I was planning on building with stock bronco axles, upgrading them and that made perfect sense to me. New I am considering dana 60's? Already this has gotten out of hand.

remember, there is no plan for heavy duty, extreme wheelin in my future plans, and if I ever did, I can change the axles then.

The high pinion full width 44, and full width 9" will be more than enough of an upgrade. Might even talk about trussing them ala landsharks recent upgrade.
Besides, I already found them, 2 44's in fact. And all I am going to be out is $200 bones that I will attempt to make up by selling the extra once I swap out the parts I do not need.

I have not mentioned this before but I have a challenge that I can have this thing ready for under 5k. So I need to consider budget as well.

Yeah, whatever dude

A real man would put hummer drivetrain under it

[Jesus_man]

Yeah, whatever dude

A real man would put hummer drivetrain under it

No. no....Land Rover...

In reality, for what you are considering Greg, I think the D44 and 9" are fine.

There are too many of us, however, who have gone down this road, and get the rock crawling bug, and then look back and go, dang, I wish I would have gone 1-ton... While it'll cost you more in the long run if you upgrade later, the axles you end up building will likely be worth some money to offset the cost of 1-tons should you go down that road.

J.D.

[hockeydad4-22]

Thank you JD, the voice of reason. I am sure this is just the first time of many during this build where I will need to resist over building this rig.

[Justin]

Reason, smeason. Go big or go home:

http://www.dynatrac.com/products/axles/portals.html

Nah, I agree with JD. Given your application (and a small hope that your sons won't be allow to 4 wheel it) I'd go Dana 44 and 9". Tons would be cool, but for even moderate 4 wheeling you're talking about more weight, cost and driveline drag without huge benefits.

[Jesus_man]

Portals is where I'd like to go!!

[hockeydad4-22]

If you want to see an over the top, spare no expense, budget blowing, beyond all reason type of build - may I suggest looking up the black cloud build on cb.com
From this side of reality, this is a rig that will be driven to the trails, will wheel well, and will drive back home. She will clean up well enough and be comfortable enough to take to work or drive the missus for a pic nic.

And most importantly, there will be no missed house payments or parts that cost more than a single house payment purchased for the project.

Sorry guys, I think that leaves the portals off the build sheet. But I will be glad to help install yours.

[Colorado75bronc]

I'll sell you the full width 9" rear thats currently under mine, with a spare center section, since I'm swapping in a Dana 60 this weekend, let me know if your interested, I'll treat ya good on the price

[hockeydad4-22]

Picked up Cory's 9" and spare center section last weekend, and I am picking up the HP-D44's this afternoon. Also picked up his old wheels - nothing to fancy at this point. But will need some skins for them so I can get it to "roller" stage soon.

Next on the list:
Radius arms
rear springs (or complete lift kit if anyone has a good one they are not planning to use - I have an old set of 3.5" coils I will use for now so a set of rears would be awesome)
Steering
Front sheet metal (all of it - though I am planning to build a tube frame instead of inner fenders)

On the 4th - I will spend the day in the garage installing disk brakes on Daniels 66 stang, after that, Wilma is my primary project. I hope to have the frame stretched and re-welded this weekend. Ordering steel today.

[akaFrankCastle]

Remind me, are you going full width?

Since you're stretching, and on a budget, maybe throw some F150 rear leafs under it?

[hockeydad4-22]

Remind me, are you going full width?

Since you're stretching, and on a budget, maybe throw some F150 rear leafs under it?

I am going full width. What are the advantages of the f150 springs? I picked up Cory's FW 9" he ran EB leafs but if f150 springs are better I am open to them.

[akaFrankCastle]

Advantages? Not really sure about the mechanical advantages. But at 18 bucks a piece at the U Pull and Pay, financially I'd say they are pretty good.

[hockeydad4-22]

Advantages? Not really sure about the mechanical advantages. But at 18 bucks a piece at the U Pull and Pay, financially I'd say they are pretty good.

Yep - hard to beat that price! Thanks.

[ZOSO]

I have a set of stock rear leaves from a eb. The only thing with the f150 springs are they are 3" wide and not 2.5" like the eb.

[hockeydad4-22]

I have a set of stock rear leaves from a eb. The only thing with the f150 springs are they are 3" wide and not 2.5" like the eb.

My Axle is from a full size and still has the perches from it (3" wide) so that is no issue, but I will need shackles to match them if I go that dirrection. I will need shackles either way - I have none.

I have 3.5" lift coils for the front so I think I need to find some leaf springs with a similar lift just to make it easier...

[Colorado75bronc]

I would run eb leafs those f150 ones would be way overkill, then you'll have to change shackles, and cut off the leaf spring hangers that are already welded to the rear of your frame, that's a buttload of work without much gain if any, just keep your eyes peeled on here and Craigslist for some rear 3.5" leafs

[hockeydad4-22]

Picked up my front axle last night as well as an extra housing. Axle came with radius arms, springs, buckets, and complete including all the brake parts.

it is from a 78. Currently has 3.53's but the extra housing has the 4.10's I want.

The seller is a cool dude, has a bad ass 78/79 bronco, a number of of 70's f150 - f250 trucks and broncos. He is looking for an eb 9" for a hot rod project of his. I gave him a card and told him to check us out.

I can't wait to get work started on Wilma.

[kchaser]

A lot of 1 ton haters I guess. The only extra expense is the axle itself. Weld some wedges on the front and a track bar mount some perches on the back and bolt them in.

[hockeydad4-22]

Figured I needed to post at least one pic of the new parts...

Wilma's new front end

[hockeydad4-22]

A lot of 1 ton haters I guess. The only extra expense is the axle itself. Weld some wedges on the front and a track bar mount some perches on the back and bolt them in.

Naw - not a hater at all. Just not wanting to build that rig at this time. Might upgrade someday - but for right now - the full width 44 / 9" combo is plenty.

[landshark]

A lot of 1 ton haters I guess. The only extra expense is the axle itself. Weld some wedges on the front and a track bar mount some perches on the back and bolt them in.

Naw - not a hater at all. Just not wanting to build that rig at this time. Might upgrade someday - but for right now - the full width 44 / 9" combo is plenty.

i think you will be super happy with that combo. I know allot of fullsize guys who abuse the 44 and 9 and it they haven't had much of a problem.

[Colorado75bronc]

Updates man! What have you done so far?

[hockeydad4-22]

Updates man! What have you done so far?

Not a lot - been very busy with other stuff, not much time to spend in the garage puttering about. I did install disc brakes on my 18yr old's 66 stang, and a complete rear brake rebuild - yes everything from the backing plates out is all new.

Also pulled the top off the 16 yr old's 74 bronco - and helped him install a pieced together stereo... and it looks like we will be replacing his rear main this weekend - along with changing the intake and carb back to the stock one we have on the original motor... this one just has never really run great. I think the 4 barrel carb might be just a wee bit to big. Does not look like much work on her this weekend either.

So other than collect parts - I have not really done much.

Speaking of which.... I am starting look for sheet metal. If you or anyone else happen run across a 64-66 ford pick up bed - fleet side - I need the sheet metal. That or I need to find and cut up a tub (and I kind of hate to do that but I will).

[hockeydad4-22]

Picked up another frame last night from my "twisted" Friend for parts and pieces, as well as a few other needed parts and pieces. Then sat in his garage and enjoyed an excellent cold beverage and chatted about many things.... bronco's, builds, plans, time lines... you know - life.

Tonight the build gets started in earnest.

Mounting axles. I hope to lay out, cut and stretch the frame this weekend as well but much of that will depend on how many other honey-do tasks I am given.

[Rox Crusher]

Picked up another frame last night from my "twisted" Friend for parts and pieces, as well as a few other needed parts and pieces. Then sat in his garage and enjoyed an excellent cold beverage and chatted about many things.... bronco's, builds, plans, time lines... you know - life.

Tonight the build gets started in earnest.

Mounting axles. I hope to lay out, cut and stretch the frame this weekend as well but much of that will depend on how many other honey-do tasks I am given.

Git-r-done

[hockeydad4-22]

Started the stretch on Saturday. Kinder came over and helped a ton. After much research and measuring several times, then measuring another time again - then once more just to be sure - we cut the frame. Then cut the new sections to match exactly - ground them and drug out the brand new 2 X 4 steel tube and 1/8" plate I purchased to sleeve the inside..... Guess what? After all that measuring, I never checked the actual frame at the location of the stretch. At the ends it is 4" in the middle it is 3 1/2".... so no we did not weld in the splices.

But I will be picking up the correct steel this week and will be welding it in.

Instead on Sunday we went and checked out the reports of a 66f250 at the Aurora PNP (Thanks Mike!). The rumors turned out to be true and this afternoon we will be scavenging the bedsides for Wilma's stretch.






Also noticed this sweet ride in the parking lot:


With this personal plate:

[hockeydad4-22]

I was finally able to spend some time with Wilma in the garage this weekend and I got a lot accomplished.

I looked at the 2 X 3" steel tube I purchased for the sleeve stiffeners and decided that it would be too loose so I cut the 2 X 4 tube down to 2 X 3 5/8". While it was open I decided that a few gussets would be a good thing and added them (probably over kill but heck - a chance to practice my welding skills where they will never be seen). I actually have a legit reason for these that I will explain shortly.

On Saturday around mid day, while cutting the second one, I burned up my grinder... so I had to go out and pick a new one up. Unfortunately I made the mistake of mentioning this to my wife and she offered to go with, oh and by the way - can we make a few real quick stops on the way... Costco, TJ Maxx (Damn - I absolutely hate that store - HATE IT!!!) Safeway etc..., oh - and it is going to take her 2 hours to get ready to go too...... I just wanted to run up to home depot for a new grinder. Lost 5 frigging hrs because of that burned up grinder.

So by the time I get back to the house it is time for dinner. I throw some chicken on the grill so we can eat, open up the new grinder, play with it a bit, eat dinner, help clean up and back into the garage. Finish cutting the second splice sleeve out and call it a night.

Sunday - I weld up the second splice sleeve and fit everything together. Start measuring. Out come the lasers, tape measures, ratchet straps.... And the grinder. I have to fine tune those frame sections some. I started in the garage at 8:00 am. Have not started welding on the frame until after 1:00 pm. I am a bit of a perfectionist when it come to straight, level and plumb. Squaring a 42 yr old frame that has been cut, extended, spliced and who knows how many times twisted over the last 4+ decades and probably was never all that straight level or square when it came from the factory in the first place is no easy task. But after several hours, I believe I got her to where I am happy.

It was taking a bit longer than I planned so forgive the lack of pictures of all this, I will take some and post later.






So I've got everything tacked up - the top and outside of the frame welded up. I need to stand it on its side so I can weld the inside of the frame and across the bottom. Then I am going to bolt it up through the frame as well. I am not 100% convinced that I am getting full penetration through the 1/4" steel plate and the 2 X 3 5/8" steel splice sleeves. I did some reading and research, even on those big rig 18 wheelers - they do not weld the splices, they bolt them so I figure if I weld, puddle weld and bolt the extensions up, I will have pretty much made her bullet proof.

1. Lessons learned - do not wear shorts when welding for long periods of time - weld sunburn...

2. Have a back up grinder, I used to but we burned up the good one last winter, now the back up one is fried as well. So I will be keeping an eye on the CL tools for sale section.

3. Yes - it can be done with a cheap 110 mig welder, using flux core wire... but it sure would be nice to have a 20A gas.... someday I will have that kind of power to the garage. someday.

More pictures soon.

[Jesus_man]

Greg, are you teasing us with no pictures??

Yes, two grinders are a must. Not to mention the time saved having one setup with a cutting wheel and one with a grinding wheel. I bought at Hitachi at Costco a while back and have been happy so far. Make sure you get one with a metal head. Plastic ones don't last as long.