Slow but sure progress. Got the trac bar, tie rod and drag link mocked up. I've got the wheelbase set at 95.5" and I'm probably going to need to scoot the front axle back about half an inch as the tie rod and drag link are overlapping some. Just need to get the driver's side radius arm in after I reposition the axle and I'll be able to cycle the suspension.

One blessing in disguise when my track bar bracket tore the hole in my frame is that when I replaced the bracket, I pushed it as far forward as the bushing would allow in anticipation of pushing the axle forward. Mine is also close, but they do clear!

Got some time in the garage this weekend. Finally got around to changing the wheel bearings on the longer axles and finishing assembly on the rear axle. Just need to fab some shock mounts and the rear will be done. Installed the caliper bracket and spindle on the driver's side so that I could check clearance on things as I cycled the front axle. Definitely glad I moved it back some. The clearance issues are a pain with only moving it forward an inch since I'm trying to keep the COG low while maintaining decent uptravel. Had to throw a tire on the rear while I was at it to get a sense of how it'll look when it's done. It's amazing how much bigger the 37's look compared to the 35's. Still not in love with the wheels, too shiny. I also moved the track bar bracket over about 3". This improved the geometry and freed up a bunch of room for the hydraulic assist. It also did a better job of bracing in all the bracketry on that side. Next up is the fabrication of some upper and lower mounts for the coilovers. I've got an idea for the lowers that will be nicer and stronger than the ones that came with my brackets, and will get met at least an inch of additional uptravel.

What is hitting first?

Looks like with the axle any further forward, it would hit the front of the inner fender first?

Yup, inner fender. I think you saw my other thread. I'm going to put a bend in the trac bar to give a little more wiggle room under the oil pan, which will make it worse.

Got a few spare minutes in the garage to bend up the shock hoops and tinker with how I want to do the joinery.

Progress remains slow but steady. I've got one coilover tower assembled and the parts fabricated for the other. They're set up so that the horizontal tube extends through both sides of each framerail to better distribute the load. I've also partially finished the rear shock towers (the tubing bender is one of the few tools quiet enough to run after the kids are in bed) and begun fabrication of the lower shock mounts for the front axle. They'll provide two mounting points for the coilover about 2 inches apart, giving me some adjustability in the angle of the coilover. It'll allow me to soften the spring and damping rates and increase wheel travel if I'm going to go hit a hard trail but have a stiffer shock for more roll control and better handling on the street. I'm also integrating the landing pads for the air bumps, which I'm planning to mount directly inboard of the coilover if there ends up being room. Finally, I scored a g deal off Craigslist on some almost new Superior chromoly axles and locking preload nuts for the front end. I'll have a little time this weekend and am hoping to get the other coilover tower finished up, the frame reinforced where the track bar mounts, and maybe the lower mounts completed.

This thing is going to be a beast

Thanks! Beastliness is the goal.

Got some garage time today. Most of it I spent crafting these custom cardboard inner fenders. Gonna cover them with duct tape and reinforce them with chewing gum and baling wire. What's a Bronco without duct tape?

That's the plan. I'm using perforated sheet and am going to put them in with screws.

Needs some final shaping, but here's the finished inner fenders. Should keep some of the chunks out while still helping keep things cooler. Also finished up the driver's side coilover hoop. Just need to complete the lower mounts and locate the uppers and then I can move on to making the cross brace.

Sexy Bronco lace.

Cut out a box in your hood, put some of that underneath, and put a lid on it. Trail oven.

Looking pretty sweet... amazed you get anything done helping everyone else all the time.

Thanks! The club has given lots to me, and I'm glad for chances to give back. Got the lower mounts mostly finished today. Just need to tack on the upper track bar mount and the upper coilover mounts and the suspension will be fully mocked up. Hope to make some progress tomorrow, as I've got the day off work.

So, let's say I was planning on a 4 link down the road. How insane would I be to just bite the bullet and do it now while I've got it up on jack stands? I've already got the rear coilovers and most of the link material. All I'd need is a truss, brackets and rod end-type things. The plan had been to do the front and then EFI, but I'm thinking it'd be nice to just get the suspension done. Thoughts?

DO IT!

Having done my 4 link before EFI I would do the EFI before the 4 link. That is IF you had to choose one or the other. The 4 link doesn't give you as much capability as the EFI does. I love my 4 link but I love my EFI more.

Crawler, thats sort of my thinking. Both will likely happen, just a matter of the order.

Boy, that's tough. If you didn't have yours apart right now, I'd also lean toward EFI. But, since she's under the knife already, it seems logical to go ahead with the 4-link. Have you done any calculations as to how to assemble the 4-link? Often times the design is 60% the battle over the fabrication part.

I've tinkered with the calculator a little, but not seriously enough to matter.

Hit a great milestone today-got the front suspension fully mocked up! I may still move the coilovers up a half inch to an inch. I'd rather not, as I don't want to cut the fenders any more than I have, but think I may be impeding some useful uptravel. This is with about 5" of uptravel. If I want more I'll need to move the tops of the coilovers up into the engine compartment and relocate the steering box forward about half an inch. I'm also not sure that I'll be able to use more without seriously massive sheet metal trimming. Next step after I burn in the axle brackets might be to reinstall the spindles and flex it out with the tires on it. Suspension gurus? What do you think? I can take some more pics if it'd help.

Also discovered that the 2nd set of 12" coilovers I bought is actually a 14" travel set. I'm actually really good with this, as I've mostly decided to mount the shocks on the back side of the axle when I link the rear end, so this will more than give me back the travel I'd lose in the process.

Good work! Throw your tires on and that may make the decision for you.

Progress continues to be slow but steady. I've got the passenger's front brackets fitted and finish welded, and spent today welding the axle tubes to the center section and filling in the plug welds. Over-built continues to be the name of the game. I'm hoping to get the driver's side finish welded tonight, then can get get the landing pads and mounting brackets for the hydro bumps located and fabricated.

Man that's a lot of geometry!