BADASS! It runs. The Diesel Bronco Build Thread

[Vetteboy]

Some of you know about the side-project I've been working on with my friend Wil, who is that infamous 'guy I know who owns a junkyard'. He's always been really into Broncos, with his most current DD being a '91 Eddie Bauer, with a Mustang GT 5.0, 5-speed and manual transfer case, HP44 SFA swap, and a semi-float 10.25" rear.

Well, in June the clutch went on it. About that same time we got this beauty in at the junkyard:

http://www.phatserver.net/users/chris/recent/bc2.jpg

'94 Ram 3500, cummins diesel.

Since he had been more than unhappy with the Mustang 5.0, and since the trans had to come down anyway to do the clutch...why not swap in a cummins?

http://www.phatserver.net/users/chris/recent/bc5.jpg

Of course it isn't quite that simple. The donor Dodge was only 2WD, so we had no transmission sitting around that would bolt up and be 4WD. However, we did have a ZF 5-speed from a 7.3L Powerstroke motor. Through a little digging, we found an obscure conversion company (www.fordcummins.com) that specializes in these things, and they manufactured us a bellhousing adapter to mate the Ford ZF to the Cummins motor.

http://www.phatserver.net/users/chris/recent/bc20.jpg

This conversion uses the Dodge flywheel, clutch, and pressure plate, which were upgraded to Centerforce II pieces. The pilot bushing is a custom piece that came with the adapter plate. The stock Ford slave cylinder and clutch arm are used with the Dodge throwout bearing. The Dodge starter is reused as well, but is relocated to spot where the Ford starter used to be. This fits the chassis nice, but required a little bit of grinding on the inside of the bellhousing in order to fit the nosecone properly.

Next, we decided the stock Borg-Warner t-case wasn't badass enough. So we did a little more digging and found a Ford NP205 case from a '79 Bronco. With a little trimming of the mounting flange on the trans to clear the shift rails, it bolts right up.

http://www.phatserver.net/users/chris/recent/bc13.jpg

At this point, the project took a big halt. My friend went back to school for a few days a week, the EPA did an inspection at the yard and found a bunch of stuff that needed to be taken care of, so that left no time for the buildup.

Sometime during that lull, we decided that after test-fitting everything, it was gonna be a bit tight. So we found a 3" body lift kit sitting in a dusty box in the basement, and figured it would probably solve all the clearance issues. Around that same time, a near-mint '96 Bronco rolled into the yard, being scrapped due to flood damage. Since my friend's '91 had all kinds of body rust, and we pretty much had to pull the body anyway to do the body lift...why not swap over the nicer, newer one?

So the body came off, which made test-fitting and mounting the motor much easier.

http://www.phatserver.net/users/chris/recent/bcnew1.jpg

Note the onboard air bottle, and the missing front crossmember - we cut it out and are almost finished with the engine cradle that will hold the Cummins motor. We also raised the gas tank up a few inches because we were bored.

Here's the powertrain as it sits:
http://www.phatserver.net/users/chris/recent/bcnew2.jpg

12-valve Cummins, with Banks turbo kit (why not?), Ford ZF 5-speed, Ford NP205, with a PTO hydraulic pump on it. This was added as an afterthought, just because we had it sitting around.

And, installed in the chassis:
http://www.phatserver.net/users/chris/recent/bcnew3.jpg

The last few weeks have been spent making the crossmember for the motor mounts, and also running fuel supply/return lines. Tonight, after securely bolting everything down, we finally got to try firing up the motor. And man, does this thing run!

http://www.phatserver.net/users/chris/cumminshi.wmv (23 mb)
http://www.phatserver.net/users/chris/cumminslo.wmv (10 mb)

Frame seems to be flexing a little bit, but we'll be adding a bit more reinforcing down the length of it. Plus with the body installed plus shocks and stuff it shouldn't be too bad.

As far as axles go...the ******* got a HP60 from a '78 F250 for free (some guy just junked the truck without knowing what he had), so that'll be going in, and we've got a D70u for the rear. He ALSO got a set of 5 Goodyear MT military tires, 37x12.5R16.5 for free, with 4 being brand new. Guess there are some perks to owning a place like that.

As it continues I'll update this, but it's lookin pretty good. If anyone wants more detail on any aspect of the build just let me know.

[MBood82]

sounds like it should be a pretty sweet truck

:thumbsup:

[Vetteboy]

Yeah, and I'll sometimes get to use it to tow the XJ as well. :D If I thought the 5.9ZJ was good, I can't wait to see how this thing'll pull...

[MBood82]

you think with the short wheelbase and 37" tires it will really do that great?

[Vetteboy]

you think with the short wheelbase and 37" tires it will really do that great?

The tires are load rated for some obscene high amount (straight off the armored humvees), the wheelbase is 106", and the springs are stiff as hell...I think it'll be fine. Even my ZJ doesn't get pushed around hardly at all by the trailer, and this thing'll be heavier, stiffer, and longer.

That last part didn't sound right.

[96 Sport]

:roflmao: :roflmao: :roflmao: :roflmao:

[XJ Fanatic]

awesome dude, just simply awesome.

If i can ever stumble across a cummins outta a ram, in she goes to the ramcharger... no real clearancing needed :brows:

[jeepkid05]

How much does the cummins 5.9 weigh compared to a jeep 4.0 lets say:brows:

[WagoneerXJ]

So if it runs, is it finished somewhat? I'd love to see finished pics with the body on and the engine in. :pimp:

[YJeff]

that is so hott, i can feel it from here. totally awesome project. :thumbsup:

[Vetteboy]

So if it runs, is it finished somewhat? I'd love to see finished pics with the body on and the engine in. :pimp:

I know you would, Ford Boy. :f2:

We gotta put the finishing touches on the crossmember...but after that, next step is mounting the body on, minus front clip. Hook up the steering, heater, brakes, trans, cable shifters for the 205 (:brows:), all that kind of stuff. Next is bolting the fenders on, last is figuring out the radiator and all that crap. So it's getting there, the hardest parts have been done...now it's just the little crap that keeps popping up.

[FitchVA]

that's killer!

[getstuck]

Ever since we were talking about it at Rausch, I've been wondering about it. That's great that it's running, I want to see him wheel it. :thumbsup:

[xj_man_646]

wow. sounds very badass. keep it updated

[Vetteboy]

Did some work on the t-case shifter setup today.

http://www.phatserver.net/~chris/bronco/cable1.jpg

You can see the cutting/grinding needed to clear the shift rods:

http://www.phatserver.net/~chris/bronco/cable2.jpg

Here are the cables we're using: push/pull, load rated to 100 lbs, from McMaster-Carr...about $40 each.

http://www.phatserver.net/~chris/bronco/cable3.jpg

http://www.phatserver.net/~chris/bronco/cable4.jpg

At this point, I'll let the pictures do the talking...

http://www.phatserver.net/~chris/bronco/cable5.jpg

http://www.phatserver.net/~chris/bronco/cable6.jpg

http://www.phatserver.net/~chris/bronco/cable7.jpg

http://www.phatserver.net/~chris/bronco/cable8.jpg

http://www.phatserver.net/~chris/bronco/cable9.jpg

http://www.phatserver.net/~chris/bronco/cable10.jpg

http://www.phatserver.net/~chris/bronco/cable11.jpg

http://www.phatserver.net/~chris/bronco/cable12.jpg

There will most likely just be some sort of plate that bolts through the hole in the shift rods, that'll get push/pulled via the cables.

After the body goes on, shift lever fabbin' will be next...and I think we're gonna do something pretty nifty for that.

[Vetteboy]

We also started setting up the radiator and intercooler.

http://www.phatserver.net/~chris/bronco/radiator2.jpg

http://www.phatserver.net/~chris/bronco/radiator3.jpg

Those are two Taurus electric fans, with a big relay that'll be triggered by a temperature switch/controller on a coolant hose. We went with the twin electrics instead of the mechanical due to space constraints...as it is, the whole front clip will likely have to be custom, with a big possibility of having a one-piece front that tips forward.

There's plenty of room for the intercooler and radiator hoses though, which is a good thing. The factory Dodge radiator hoses will work fine.

[GrandJeepin]

macmaster carr :rock:

[Vetteboy]

Dude, lemme tell you about mcmaster-carr...

Those cables were ordered at 1 AM on a Friday...meaning a very late Thursday night. They arrived ON that Friday, via standard UPS ground. That means a same-day order on the website AND delivery. Gotta love that.

Not to mention, I ordered a few drill bits and bolts and junk for my longarm project, and it came really quick, and the stuff was top-notch quality. I got a 9/16 and a 5/8 drill bit from them, and those things are still sharp after doing the whole longarm project and a bunch of stuff on this bronco. Awesome company and their website is really nice too.

[MBood82]

at work we order from mcmaster carr on an almost daily basis. it almost always arrives the next day and they discount stuff for us since we are a university lab.

their website is a little untraditional at first but once you get used to it, it is very useful. :thumbsup:

[getstuck]

Is the flooded 96 Bronco still around? I need some parts from it. :dunno:

[Vetteboy]

Is the flooded 96 Bronco still around? I need some parts from it. :dunno:

What are you looking for? We're gonna be using the whole body + most of the interior, as far as gauges and whatnot go...unless you need some kind of drivetrain or engine management stuff, it's probably already taken. But I'll check and see anyway.

[getstuck]

I need a straight rear bumper and some dash trim for my buddy with the other camo's 79 from NY. He was at RC with us.

[JeepXJ3]

I dont know about you, but I seemed to always be pulling Bronco's out of the woods...

http://img.photobucket.com/albums/v18/JeepXJ3/Kevins%20Bronco/IMG_1087.jpg

http://img.photobucket.com/albums/v18/JeepXJ3/Kevins%20Bronco/IMG_1095.jpg

http://img.photobucket.com/albums/v18/JeepXJ3/Kevins%20Bronco/IMG_1089.jpg

Bronco has since been sold and completely overhauled. No more rust and a fresh paint job. No more trails for this pig.

(Ford finally found the problem... Then circled it!)

[NickDCJ7]

Hey chris, you do know that McMaster is all of about 15 minutes away from you, right? They're in Edison, i think. And yes, they are always fast with their shipping to us too.

[Vetteboy]

Got an absolute ***-load of work done on it today. There's light at the end of the tunnel.

First, I finished up the cable shifters for the 205, at least on the t-case. It ain't the prettiest thing but it works great.

http://www.phatserver.net/~chris/bronco/cable13.jpg

http://www.phatserver.net/~chris/bronco/cable14.jpg

That lil nut fits right in the shift rod, so hey, tighten 'em up and go for it.

Next, since all the chassis work was done, we hauled it out of that garage and into one of the lift bays, where the body was waiting.

http://www.phatserver.net/~chris/bronco/body1.jpg

That's our airport tug that we use for moving crap around.

Gettin the body ready to drop on...

http://www.phatserver.net/~chris/bronco/body2.jpg

Here's the body mounted up...the exposure is a little off, but it's that darker teal color...we're not sure if it's staying or not. We've also got the steering hooked up at this point, so it made steering it into the bay a lot easier.

http://www.phatserver.net/~chris/bronco/body3.jpg

Clearance shot of the motor installed. Good amount of room between it and the firewall.

http://www.phatserver.net/~chris/bronco/body4.jpg

Looks almost like it belongs there...

http://www.phatserver.net/~chris/bronco/body5.jpg

Turns out (as expected) that we had to edit the front header panel to make everything fit. After some measuring and cutting, we managed to fit both the radiator and intercooler, while maintaining the stock shape of the front, and also the hood latch. At this point, I also did a little modding of the throttle cable bracket, so the truck now has steering and throttle control.

http://www.phatserver.net/~chris/bronco/body6.jpg

Since we were on such a roll, we figured we'd mount up a few of the Goodyear Wrangler MT humvee tires (37x12.5R16.5) and see how it worked. This is the bronco's owner, who's a tiny bit over six feet tall...I'd say it looks pretty badass. This is also after we got the grille mounted back up and decided that it was gonna work after all.

http://www.phatserver.net/~chris/bronco/body7.jpg

We then went and got his bumper out of storage...this bumper we built about a year ago.

http://www.phatserver.net/~chris/bronco/body8.jpg

It started life as a wrecker push bumper. We reinforced and changed up the mounting, then added plow mounts, and also the 12k winch. Yes it's heavy, and yes it kills the approach angle a little bit, but it does what he wants it to do. The way we built it, if the plow's on there, we can lower the plow down and use it as an anchor while the winch line goes over it.

So now, we can start the motor from inside the cab, we have throttle and steering, and the radiator and intercooler fit fine inside the stock nose. The t-case shifter cables are inside the cab as well and are ready to be lever-ized. All chassis electrical is set to go (taillights, headlights, tailgate window motor, etc), and the motor only requires two wires from inside - fuel valve solenoid (always on when key is on) and the starter solenoid, both of which are easy. Looks like this thing might get done after all.

[JeepXJ3]

wow... that things starting to look like a mean little pony... Bumper I would do some changes to, not many just those necessary to improve its offroadability.

Lets see more!!!

[xj_man_646]

maybe you discussed it, maybe not...but are you guys doin any frame mods to it?

[HotSEXJ]

that bumper is the juggernaut, b!tch!

[XJ Fanatic]

lmao to hunter

And wow chris you got a **** load done, and reply to your PM's whore

[getstuck]

Hmm is that stock Bronco bumper still around? :D

[WagoneerXJ]

Bad A.S.S. man. Looks real good. Does it move yet?

[Camel_Joe]

That's awesome! I like the 91 body style over the 96 though. What kind of reinforcement did you do to the frame?

Could you drop the pass side Bronco badge, from the 91, in an envelope and send it to me. Mine fell off. I'm far too lazy to go to the junkyard myself.

[Vetteboy]

Yay pictures.

We got the regulator and charging issue figured out. This lovely Leece-Neville heavy-duty regulator came from an old school bus. It's got an adjustable field voltage so we were able to tune it for the Dodge alternator. It maintains a perfect 13.8-14.1 volt charge throughout all load and RPM ranges.

http://www.phatserver.net/~chris/bronco/regulator.jpg

Here's a shot of the nearly completed engine compartment.

http://www.phatserver.net/~chris/bronco/engine.jpg

Dual optima batteries, flanking a dual-electric fan setup (both are Taurus fans). The fans are temperature controlled via a sensor on the radiator hose. We used an overflow bottle from a Jeep Cherokee:

http://www.phatserver.net/~chris/bronco/bottle.jpg

and this K&N air filter, selected after rummaging through about 20 different boxes at the local Wal-Mart.

http://www.phatserver.net/~chris/bronco/filter.jpg

It's mounted to the firewall via a small bracket and some sheet metal screws.

So what's left, you ask? Brakes, which should be done on Monday. The steering needs to be revised (however the Dodge power steering pump is hooked up to the Ford box and works just fine). Another inch of lift will be added to the front to level it out and give a bit more clearance for the HP60 - it's not in there yet, the Hp44 is staying for a little while, but now's the time to do it. Then driveshafts, and interior, and it'll be rollin.

All gauges are now hooked up, including wait-to-start and water-in-fuel, wired to the special diesel indicator panel from a '95 Powerstroke. Looks perfectly stock. Chassis electrical is all done, and with the alternator done, pretty much all wiring is ready to be cleaned up and tucked away. It's gettin close, and with the warm weather coming, we'll be working that much harder.

[Blaine B.]

Looks superb, nice work you're doing. Lucky owner too......keep it up!

[Vetteboy]

After a few months of bull****, we drove this thing for the first time yesterday. Got it up to roughly 45 MPH or so.

What the hell have we done... :o

There's something about 1900 RPM, 3rd gear, turbo spools up to 25+ lbs, and suddenly your speed is doubling...

More on this later.

[MBood82]

pics and or video are required at this point...

[HotSEXJ]

:eek:

[cruiser]

that guys got the coolest yard ive ever seen

[Aidan]

pics and or video are required at this point...
x2

[WhyJay]

pics and or video are required at this point...

preach on my brotha

[WagoneerXJ]

I still love this project. more updates!

[MBood82]

i'm still waiting...

[Vetteboy]

i'm still waiting...

Here ya go. :corn:

Video posted.

Keep in mind that this is NOT the finished product - this is "hey, we have it rolling under its own power, let's see what else we still gotta do." The front axle especially has to go; it's still a HP44 with 8-lug Chevy 10-bolt outers on it, and has that wonderful camber issue that often happens (noticeable in some shots). Also we've got four matching wheels (to match the right rear one) that are wider with less backspacing which will help to make it look less tall.

That being said...turbos are awesome. :f2:
http://www.tcnj.edu/~macock2/stuff/broncocummins.wmv (9.2 MB)

Enjoy!

[MBood82]

i'm buffering....

lookin forward to it...


*edit* that thing was awesome!

[Mo_Corley]

I want one :rock:

And use a tripod. You are shaking like a dog takin a ****!:drunk: :lol:

[Krazy]

that thing is fawking nuts, i want it

[Aidan]

i think its a terrible idea and no one should own a vehicle like that :p

its a sick truck, im jealous :evil:

[WagoneerXJ]

Wow, that was cool! Not gonna do any burnouts? :p

[Hoofmann]

That thing is sweet!!