WELCOME TO JOE'S BRONCO PAGE

The New Build Up

  This page is dedicated to the build up of my '71 EB.  I've had several EBs over the years, trying to do everything with one truck, but recently had an epiphany.  I decided to have one EB as a daily driver and another to be the rock beast.  This is the story of the rock beast...

OTHER PAGES:
    Main Page
    NP203 Doubler Page
    Scout II PS Setup and Tube Front Sub-frame 


Design Parameter #1:  Keep the complete trail ready weight under 3500#

I know, it's going to be hard!
 

Before The Build Up:

How it looked before I started the build up to make it a primarily trail truck

UPDATE  29 December 2002

This page got too busy, so I created another for the continuation of this build up.  Click here to go there.


02 June, Got a couple more things done

 
 Welded in Tool Box under passenger seat
 Shelf under hood, used to be heater
 Mock up of new cage, still needs finish welding.  Also, note color of rear panel.  This will be the new color.
Final mock up of cage, still needs finish welding, I ran out of gas! 

The Scout Power Steering Gearbox


Front 1/4 view of Scout box and tie rods
Side view of same

05 May, Test fit the new body!!!

Cut rockers with welded in 2"x6"x1/8" protection, still have to expand the wheel openings.


Side view, not a special camo job, just testing paint colors on the fender
This is 4.5" suspension and 2" body lift
The welded in Rocker protection
Close up of front wheel opening, still needs triming to fit right
Close up of rear wheel opening, also needs triming

This body has been a bit of work to get fixed up and ready for installation, but it's in a LOT better shape than the old blue one was.  Where the floorboard to rocker panel seam was, there was no metal for 2" in any direction.  Since I'd undercoated both sides of the tub a couple of years ago when I first got it, there was no easy way to fix it.  I welded new metal in for both floorboards, made some additional metal reinforcing for the kick panel to floor seam, replaced the corroded drivers side body mount under the floor, cut off the offending sheetmatal and added the rocker protection.
 
 

PLANS:

Item
Currently
Comments
  Engine   '90 E250 EFI 300 Cubic Inch Inline 6 Cylinder  
  Aspiration   MAP EFI, Stock EEC and wiring  
  Transmission   Stock C-6 from a 4x4 '85 Bronco with tow package
  Doubler   Chevy NP203 Range box and custom adapters   Won't go back to the manual tranny till the hybrid front axle is in.
  Transfer Case    Ford NP205  
  Steering:    Saginaw HD PS pump and tie rod over knuckle with the HD Chevy ends   
  Body    Decent brown '75  
  Safety   Big Cage  
  Front Axle   Full width Disk Brake equipped High Pinion Dana 44 from a '77 F150  With 4.88 gears, Moser shafts and ARB
  Rear Axle   Full width Big Bearing '77 F150 axle with drum brakes    May swap to disks
  Seats   Fronts are Summit Racing Buckets, no rear seat planned  
  Tires   38.5x14.5x15 Swamper TSL SX or 35x12.5x15 MT/R   Have both
  Lift   Not sure yet, about 5-6" in a combination of body and suspension.  
  Suspension   I want to do a link type and coilovers, but too many questions just yet   .Maybe next winter
  Ignition   Probably use an MSD or Jacobs   
  MPG   It's a trail rig, who cares!  
 On-board Air   Probably, gotta figure it out  
 Wheelbase   The front is moved forawrd about 6" and the rear is moved back 3.25"  
  Weight   Under 3500#  No doors, tailgate, top, inner fenders, what else??  

 
 

The Build Up:

Body tub with front cut off
Engine, bellhousing and tranny mocked up
Front view of engine in frame
NP203 Doubler on NP435
Full width axles installed
Frame with shock, coil, track bar and motor mounts removed
Front axle moved 6" forward
New mounts, coil and shock mounts installed
New mounts, coil and shock mounts installed
The rear axle moved 3" back
Close up of front mount
Close up of rear mount 
Close up of engine mounts and notched crossmember
Engine in, note front clearance
Engine and C-6 mocked up
 Mocked up with the C-6 and NP203 
 
Mocked up with the C-6 and NP203
Mocked up with the C-6 and NP203 
 01 APRIL, Test fit the body!!!
 

The Build Up:

    I'd been driving and building this EB for about the last 3 years, but the body was never in good shape and me learning to drive the rocks really beat it up.  I picked up another EB fairly cheap and decided to make a daily driver and strictly trail EB from them.  By the time really got around to doing much with this one, I'd already finished stripping all the good stuff off it and building it up into the  white '74.  Now to do the trail rig with this one.   So here's how it went...

Day 1.
    Well, got the body off  the frame today and tried to put the engine in, no such luck.  The front crank pulley hits the frame crossmember and the motor mounts are too close together.  I'll try a smaller set of mounts before I hack the old ones off the frame.  I think I'm going to have to move the front crossmember forward an inch or two.  This may be good, since I wanted to move the front axle forward a bit as well.

Day 2.
    Cut the front off the body tub and pulled the last bit of stuff from the inside.

Feb 15
    I took a long break (2 weeks), I was burned out after getting the other one cleaned up and done.  So today I got my new engine hoist and put it together, then tried putting the engine in the frame to make good measurements for mods to make it fit.  Well, unlike last time, I had a little more patients putting it in.  Stock '90 E250 motor mounts in the stock '71 V-8 frame horns.  Woo Hooo!!  Doesn't look like I'll have any interference from the front crossmember as well.  Once the engine was in, I also bolted on the bellhousing and transmission to see how it'll look.  You can see in the pictures.

March 1
    Got the full width axles in.  Took the engine back out, I didn't like how high up it sat.  I knew that would move the Center of Gravity up MUCH higher than I wanted it.  The plan now is to fab up some engine mounts and then reinstall the engine.  I have the stock V-8 horns cut off the frame.  Front half of NP203 Doubler is solved, now I just need to do the back half.  I may have a line on a cheap Chevy D60, if so I'll be creating a hybrid front axle!!

March 10
    Decided I'm going to move the front axle forward.  Cut the coil towers, shock mounts and trackbar mount off the frame.  Also cut the radius arm mounts off the frame.  They were a MAJOR PIA since I had custom ones on there for the extended radius arms.  Spent about 5 hours getting all the old stuff off the frame.  It could have talken less time, but I needed to try and keep them in good shape so I can reuse them.

March 16-18
    Did move the front axle forward about 6".  Picked up a Scout II PS gearbox from the yard, I may use it depending on clearance issues once it's all set.  The pitman faces the opposite direction and it seems like a pretty good alternative to the old PS box.  I also moved the rear axle back about 3".  Overall the wheelbase should be about 100".  I wonder what the body will look like once it's all back together...

March 22-24
    Got the new engine mounts, and old coil towers and shock mounts welded back onto the frame.  Notched the front crossmember to allow clearance for the crank pulley.  Finish welded the rear axle brackets back on the frame.  All painted up and looking good.  Got the engine mounted and mocked up with a C-6 tranny from a '85 Bronco.  Painted all the old places where I had to cut/grind on the frame.  Now I need to make/mount the track bar bracket.

March 30-31
    Got a couple of little things done, nothing major since it's Easter weekend.  Welded on the inboard shock mounts in back, put the Leaf Reliefs in, all new bolts with nylock nuts in the rear springs, test fit the NP205 transfer case.

01 April
    Test fit the body today.  Pulled the doors, tailgate, seats, etc.. off it, made it as light as I could and had two neighbors help put it on there.  Not too bad, had to cut some of the firewall out, will have to cut out ALL the center section of the firewall above the tunnel cover.  It's close, but not quite on the frame mounts.  About 3/4" behind them now and the engine is hitting the firewall.

05 May
    Been working a little at a time over the last few weeks, mostly on the new body.  Had lots to replace, but I just didn't want to cut up my original, uncut '66 roadster tub to create a trail truck.  Most of the driveline is in and working, still need to do the wiring and install the driveshafts.  Got the new gears installed both front and rear.  Went with 4.88 gears, 31 spline mini-spool rear and ARB front.

02 June
    Got a few things done, cage is built and in, just needs finish welding.  Front and rear axles are ready to go, interior and body are about finished, now it's time to start on the wiring.
 
 

Created 18 November, 2001
Last Updated 02 June '02, RJLOUGEE  All rights reserved.
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