Project Bronco Diet and Makeover

[rsmith]

Well as you know the Bronco came back from February Frenzy pretty busted up. The C6 transmission lost the low gear clutches.

I contacted the good folks at JWP Customs and he supplied me with a 5.0 from a Mustang and a 2wd C6 transmission in which I am going to use my 4wd C6 to convert it over to fit my NP205 T-Case. This setup should shed about 300 lbs.

JWP Customs even allowed me to use his shop to pull the motor. While I was there Brad and Jason have convinced me to do some major body trimming (of what little is left) and build a cage. They seem to think that new motor install, cage, narrowing front grill, and much more can be completed for the Summertown ride. I guess they think we are doing Monster Garage here

One goal that I am most concerned about is building 2 more seats in the back with a safe cage that the family can ride in.

Tomorrow I will try to post some cage ideas to get some feedback if you don't mind. Craig, you have inspired us to try to narrow the front grill and fenders.

I am absolutely having a hard time waiting to hear that 5.0 fire up on the propane. I will try to post picture of the progress. Thanks again Brad and Jason for your help.

[Busted Knuckle Racing]

I like the look of this cage. It could be modified for family:

[rsmith]

That cage is pretty cool. Those curves in the rear are pretty neat.

Here are the ideas that we looked at last night that I like as well:





I am also looking at doing this to the front. It sure seems like a lot of chopping. ;D



Any advice and opinions will be greatly appreciated.

[Busted Knuckle Racing]

here is another that is not quite as narrow. I am not sure we can get yours as narrow as the blue one.

[Busted Knuckle Racing]

here is a picture album step by step:
pg.photos.yahoo.com/ph/[e-mail]/album?.dir=97d0&.src=ph&store=&prodid=&.done=http%3a//pg.photos.yahoo.com/ph//my_photos

Here is what we are going for:

[rsmith]

Well guys I started this thread thinking that I was going to do a simple motor swap and cage build, but oh what a couple of hours Saturday has changed. Jason, Brad and myself just started taking stuff apart and could not stop. I used the word "diet" loosely when I started this thread. Boy will I watch the words that I use aroud those guys again.

Well here is a progression of what the Bronco went through Sat. Basically anything that was orange or yellow got taken off of the frame.

[rsmith]

Here are my goals that I am concerned about for this tube rock buggy.

1. Must fit 4 comfortably as an addition is coming to the family.

2. I want to be able to see things better than I could w/ the big Bronco hood - front and rear

3. Somewhat easy access to the rear seats.

4. Comfort and safety are key

5. Try to stay around 4500 lbs or less. The bronco weighed 5200 when it was intact.

6. Want to use some Bronco sheet metal (grill and fenders) in the build.

Jason here are some pics that seem to meet a lot of the criteria - what do you think of the design. Imagine the narrowed Bronco grill and dovetailed front fenders.

[rsmith]

Here is the grill after I Tig welded it today. I am going to have it and some tubing sandblasted this week so that we can start bending tube soon.

[Busted Knuckle Racing]

awesome! looking good.. It is going to be just as narrow as the purple one! This is going to be one big bad mamma jamma!

[broncocraigellis]

this is my fist look at the thread. i've been i b'ham since thursday. rob, you've got some great ideas. the grill looks good, too. could you give me a measurement on the width? mine is about 42" now, i cut about 18" out of it. i've always liked grady's buggies. i assume that's what is in the buggy pics above. it's gonna be cool. what days are ya'll working on it? i'd like to come hang out one night. i'm kind of tired of looking at mine.

[Busted Knuckle Racing]

Craig, I was in Tupelo on Sunday and almost called you to see if I could come by and look at your Bronco. Hey, if you come down this way, bring that 35" spare with you whenever you come to bring Jason's Jeep hood and grill.

[rsmith]

Craig, the grill is 44" in width. We must have been scratching our heads about the same on that.

Jason and I just got through talking and I think that we have decided to scratch the Bronco frame as well and go strictly tube with Bronco body parts. The more I think about it, the more I realize that I would always look at the old frame and wish that we would have spent a little more time and done it right. So here we go with a full tube buggy build.

I am not sure when we will be working next. I am taking some tubing to get sandblasted Wed. afternoon and pick up Friday and I assume that sometimes shortly after that we will start bending tube. If we know ahead of time when we will get on it next I will let you know.

That is a Grady buggy. We may stick with that design with some alterations.

[Busted Knuckle Racing]

;D
It will be monster garage crunch time if we are doing an all out tube buggy in time for the March ride, but you will be glad you did it. Of course you know Jason is just practicing on you for when he builds Cathy's buggy.

[rsmith]

I don't think we will make it for the March ride if we go all tube.

I will just have to get an axleshaft for Project Farm Willys and try it out.

We should take our time instead of trying to hurry just for a ride - there will be other rides.

[jeepchipjones]

You definitely have a strange schedule Rob... I cant wait to see it when its done, and let me know if you need an extra hand sometime.