D60FreshOffTruck.jpg
1607 hits | 97.26 KB | Posted: 12/24/04
Front Dana 60 fresh off the truck

D70U.jpg
1375 hits | 91.24 KB | Posted: 12/24/04
D70U waiting for its turn under the wrench

D70TestFit.jpg
1251 hits | 64.55 KB | Posted: 12/24/04
First test fit of D70 under the Bronco

35OnHummerRim.jpg
1273 hits | 58.75 KB | Posted: 12/24/04
Hummer rim waiting for its turn to be refinished. That's a 35 inch tire.

New42.jpg
1325 hits | 58.94 KB | Posted: 12/24/04
New 42" shoes!

Compare42-35.jpg
1343 hits | 61.14 KB | Posted: 12/24/04
Clearance difference between 42"s and 35"s

StockTo42.jpg
1514 hits | 61.51 KB | Posted: 12/24/04
That little bitty tire was on the Bronco when I bought it.

AxleSide.jpg
2366 hits | 74.86 KB | Posted: 1/16/05
First fitup of front axle to see where things will line up. The axle is forward about two inches fr...

AxleFront.jpg
1710 hits | 69.07 KB | Posted: 1/16/05
Front view of initial fitup. Those are stock Bronco rear springs.

AxleTire.jpg
2207 hits | 54.59 KB | Posted: 1/16/05
This is about the final position for the tire. It'll take quite a bit of trimming to make this fit w...

CutHummerRunflat.jpg
1590 hits | 59.75 KB | Posted: 1/30/05
Hummer beadlock with the runflat section cut off. A little grinding on the sharp parts and it'll be ...

HangerPieces.jpg
1459 hits | 52.59 KB | Posted: 1/30/05
The parts I cut out to build a heavy duty spring hanger.

WeldedHanger.jpg
1580 hits | 52.08 KB | Posted: 1/30/05
All the parts welded up. And yes, my welding sucks.

PairOfHangers.jpg
1580 hits | 41.24 KB | Posted: 1/30/05
Both hangers with the welding finished. The one on the left has been abrasive blasted for paint, but...

BoxedFrameAndShackle.jpg
1955 hits | 57.16 KB | Posted: 2/9/05
Boxed in front frame horn with installed shackle bushing.

FrontShackleUnfinished.jpg
1493 hits | 46.36 KB | Posted: 2/9/05
These will get nice rounded ends and paint when everything is finished. Length is 6" center-to-cente...

RearHangerFinalMockup.jpg
1456 hits | 60.3 KB | Posted: 2/9/05
Final mockup of rear hanger. Definitely could have been done better, but OK for a first attempt.

WholeSpringFinalMockup.jpg
1401 hits | 75.49 KB | Posted: 2/9/05
The whole spring assembly in place. The front shackle angle is about 45 degrees at ride height.

FirstInstall.jpg
1420 hits | 60.97 KB | Posted: 2/12/05
First installation with entire suspension. Now I have to pull it all again for final touch up and pa...

AxleSupportingTruck.jpg
1394 hits | 78.24 KB | Posted: 2/12/05
Here the axle is supporting the truck. The shackle angles look good and the pinion angle looks good....

AxlePositionAtRideHeight.jpg
1431 hits | 74.55 KB | Posted: 2/12/05
The axle postion at ride height is about 1 inch ahead of where my SAS axle lined up. I should have a...

RightSideCloseup.jpg
1351 hits | 68.7 KB | Posted: 2/12/05
Close up from the right side.

LeftSideCloseup.jpg
1489 hits | 72.17 KB | Posted: 2/12/05
Closeup from the left side.

PaintedAxle1.jpg
1395 hits | 65.07 KB | Posted: 2/19/05
Rebuilt and in the truck. Tie rod won't fit above knuckles, have to work on that.

PaintedAxle2.jpg
2265 hits | 64.86 KB | Posted: 2/19/05
Too bad they don't look like this very long.

RebuiltAxle1.jpg
1571 hits | 61.98 KB | Posted: 2/23/05
The finished axle and springs. It still needs shocks, brakes, and steering to finish the front end.

RebuiltAxle2.jpg
1420 hits | 60.24 KB | Posted: 2/23/05
Another angle

OnTheNewAxles.jpg
2232 hits | 46.96 KB | Posted: 3/12/05
First time on the new axles. This should be real close to the final ride height. The axle centers ar...

TireFullSide.jpg
1642 hits | 64.51 KB | Posted: 4/23/05
42" tire on Hummer rim. The inner fender is installed in this picture. The inner and outer fenders h...

RearTire2InnerFender.jpg
1469 hits | 48.2 KB | Posted: 4/23/05
This is the clearance between the tire and rear of the inner fender witht tire turned to full lock. ...

RearTire2Spring.jpg
1294 hits | 47.11 KB | Posted: 4/23/05
At full lock the rear of the tire hits the spring. Have to adjust the steering stops.

FrontTire2RadiatorSupport2.jpg
1222 hits | 50.94 KB | Posted: 4/23/05
This is the clearance between the front of the tire and the inner fender with the tire straight ahea...

FrontTire2RadiatorSupport.jpg
1270 hits | 55.53 KB | Posted: 4/23/05
At full lock, the tire hitts the front inner fender and radiator support hard.

FrontTire2Spring.jpg
1371 hits | 58.6 KB | Posted: 4/23/05
At full lock, the front of the tire is also hard into the spring. Have to adjust the steering stops.

HubStickout.jpg
1268 hits | 36.72 KB | Posted: 4/23/05
This is part of why I chose drive flanges instead of hubs. Hubs would stick out another two inches.

Steering2Spring.jpg
1789 hits | 62.6 KB | Posted: 4/23/05
My homemade Zero Rate lift for the front spring. The steering rod will hit the spring when the sprin...

ClearanceAfterCutting.jpg
1264 hits | 73.09 KB | Posted: 5/8/05
Loads more clearance after a bunch more cutting and relocating the rad support mount.

RadSupportCut.jpg
1225 hits | 59.45 KB | Posted: 5/8/05
Removed a bunch of the radiator support. Hopefully the relocated mount will survive.

RelocatedBodyMount.jpg
1701 hits | 66.62 KB | Posted: 5/8/05
The new body mount sits on top of the frame. There is less beef in the radiator support now, time wi...

FenderCutFromInside.jpg
1342 hits | 42.3 KB | Posted: 5/8/05
With the inner fender reinstalled.

ClearanceFromFront.jpg
1288 hits | 55.27 KB | Posted: 5/8/05
From the front, the fender is opened way up. I can keep the turn signal, but just barely.

FinalFenderCut.jpg
1469 hits | 67.74 KB | Posted: 5/8/05
If you compare this to previous pictures, you can see how much inner fender is actually removed.

OnTheRoadAgain.jpg
2467 hits | 65.56 KB | Posted: 5/9/05
First test drive with new driveline!

OnTheRoadAgain2.jpg
1582 hits | 38.1 KB | Posted: 5/9/05
I kinda like this one better

FlexSide.jpg
1520 hits | 84.05 KB | Posted: 5/15/05
651 on a 30 degree ramp. Equates to 952 on a 20 degree ramp. The coil / radius arm suspension would ...

FlexFront.jpg
1499 hits | 91.37 KB | Posted: 5/15/05
Keep in mind that's a 42" tire falling out of that fender.

FlexLFSpring.jpg
1374 hits | 61.34 KB | Posted: 5/15/05
The spring goes into slightly negative arch at full stuff. Bump stops will be added to limit travel ...

FlexRFSpring.jpg
1436 hits | 71.22 KB | Posted: 5/15/05
There just isn't any more droop in this spring. The tire is barely touching the ground here.

FlexRRSpring.jpg
1345 hits | 76.4 KB | Posted: 5/15/05
It's amazing these springs have lasted. This is a 6" lift spring. The tire is fully stuffed though, ...

fender1.jpg
1187 hits | 57.8 KB | Posted: 7/2/05
Keep trimming 'til it fits

fender2.jpg
1250 hits | 65.92 KB | Posted: 7/2/05
Not much left