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 D60FreshOffTruck.jpg | Hits: 1681 | Size: 97.26 KB | Posted on: 12/24/04 | Link to this image
Front Dana 60 fresh off the truck
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D70U waiting for its turn under the wrench
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First test fit of D70 under the Bronco
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 35OnHummerRim.jpg | Hits: 1336 | Size: 58.75 KB | Posted on: 12/24/04 | Link to this image
Hummer rim waiting for its turn to be refinished. That's a 35 inch tire.
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Clearance difference between 42"s and 35"s
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That little bitty tire was on the Bronco when I bought it.
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First fitup of front axle to see where things will line up. The axle is forward about two inches from stock.
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Front view of initial fitup. Those are stock Bronco rear springs.
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This is about the final position for the tire. It'll take quite a bit of trimming to make this fit with a low lift (4-6 inches).
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 CutHummerRunflat.jpg | Hits: 1658 | Size: 59.75 KB | Posted on: 1/30/05 | Link to this image
Hummer beadlock with the runflat section cut off. A little grinding on the sharp parts and it'll be ready for installation.
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The parts I cut out to build a heavy duty spring hanger.
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All the parts welded up. And yes, my welding sucks.
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Both hangers with the welding finished. The one on the left has been abrasive blasted for paint, but both need final cleanup and some more massaging.
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 BoxedFrameAndShackle.jpg | Hits: 2025 | Size: 57.16 KB | Posted on: 2/9/05 | Link to this image
Boxed in front frame horn with installed shackle bushing.
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 FrontShackleUnfinished.jpg | Hits: 1560 | Size: 46.36 KB | Posted on: 2/9/05 | Link to this image
These will get nice rounded ends and paint when everything is finished. Length is 6" center-to-center.
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 RearHangerFinalMockup.jpg | Hits: 1518 | Size: 60.3 KB | Posted on: 2/9/05 | Link to this image
Final mockup of rear hanger. Definitely could have been done better, but OK for a first attempt.
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 WholeSpringFinalMockup.jpg | Hits: 1474 | Size: 75.49 KB | Posted on: 2/9/05 | Link to this image
The whole spring assembly in place. The front shackle angle is about 45 degrees at ride height.
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First installation with entire suspension. Now I have to pull it all again for final touch up and painting. These are stock Bronco rear springs.
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 AxleSupportingTruck.jpg | Hits: 1468 | Size: 78.24 KB | Posted on: 2/12/05 | Link to this image
Here the axle is supporting the truck. The shackle angles look good and the pinion angle looks good. The front axle is parallel to the rear within about 1/32 of an inch.
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 AxlePositionAtRideHeight.jpg | Hits: 1504 | Size: 74.55 KB | Posted on: 2/12/05 | Link to this image
The axle postion at ride height is about 1 inch ahead of where my SAS axle lined up. I should have about 106 inch wheel base, or two inches over stock.
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 RightSideCloseup.jpg | Hits: 1421 | Size: 68.7 KB | Posted on: 2/12/05 | Link to this image
Close up from the right side.
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 LeftSideCloseup.jpg | Hits: 1552 | Size: 72.17 KB | Posted on: 2/12/05 | Link to this image
Closeup from the left side.
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Rebuilt and in the truck. Tie rod won't fit above knuckles, have to work on that.
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Too bad they don't look like this very long.
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The finished axle and springs. It still needs shocks, brakes, and steering to finish the front end.
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First time on the new axles. This should be real close to the final ride height. The axle centers are 21 inches off the ground.
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42" tire on Hummer rim. The inner fender is installed in this picture. The inner and outer fenders have been heavily trimmed.
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 RearTire2InnerFender.jpg | Hits: 1543 | Size: 48.2 KB | Posted on: 4/23/05 | Link to this image
This is the clearance between the tire and rear of the inner fender witht tire turned to full lock. Not much vertical movement available.
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 RearTire2Spring.jpg | Hits: 1364 | Size: 47.11 KB | Posted on: 4/23/05 | Link to this image
At full lock the rear of the tire hits the spring. Have to adjust the steering stops.
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 FrontTire2RadiatorSupport2.jpg | Hits: 1288 | Size: 50.94 KB | Posted on: 4/23/05 | Link to this image
This is the clearance between the front of the tire and the inner fender with the tire straight ahead.
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 FrontTire2RadiatorSupport.jpg | Hits: 1338 | Size: 55.53 KB | Posted on: 4/23/05 | Link to this image
At full lock, the tire hitts the front inner fender and radiator support hard.
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 FrontTire2Spring.jpg | Hits: 1440 | Size: 58.6 KB | Posted on: 4/23/05 | Link to this image
At full lock, the front of the tire is also hard into the spring. Have to adjust the steering stops.
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This is part of why I chose drive flanges instead of hubs. Hubs would stick out another two inches.
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 Steering2Spring.jpg | Hits: 1856 | Size: 62.6 KB | Posted on: 4/23/05 | Link to this image
My homemade Zero Rate lift for the front spring. The steering rod will hit the spring when the spring is flexed. I'll have to put the overload leaf back in.
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 ClearanceAfterCutting.jpg | Hits: 1332 | Size: 73.09 KB | Posted on: 5/8/05 | Link to this image
Loads more clearance after a bunch more cutting and relocating the rad support mount.
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Removed a bunch of the radiator support. Hopefully the relocated mount will survive.
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 RelocatedBodyMount.jpg | Hits: 1774 | Size: 66.62 KB | Posted on: 5/8/05 | Link to this image
The new body mount sits on top of the frame. There is less beef in the radiator support now, time will tell if this was a good move.
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 FenderCutFromInside.jpg | Hits: 1407 | Size: 42.3 KB | Posted on: 5/8/05 | Link to this image
With the inner fender reinstalled.
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 ClearanceFromFront.jpg | Hits: 1354 | Size: 55.27 KB | Posted on: 5/8/05 | Link to this image
From the front, the fender is opened way up. I can keep the turn signal, but just barely.
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If you compare this to previous pictures, you can see how much inner fender is actually removed.
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First test drive with new driveline!
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I kinda like this one better
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651 on a 30 degree ramp. Equates to 952 on a 20 degree ramp. The coil / radius arm suspension would do about 700 on a 20 degree ramp.
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Keep in mind that's a 42" tire falling out of that fender.
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The spring goes into slightly negative arch at full stuff. Bump stops will be added to limit travel since the tire is into the firewall at this point.
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There just isn't any more droop in this spring. The tire is barely touching the ground here.
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It's amazing these springs have lasted. This is a 6" lift spring. The tire is fully stuffed though, it's hitting the inner fender and cannot go any further.
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Keep trimming 'til it fits
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Front D60 Install
