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one ton upgrade

From 1994 Ford Bronco “Plug Ugly”, documented by Damon Haas.

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1994 Ford Bronco - in the beginning 1994 Ford Bronco - passanger side spring and sway bar mounts 1994 Ford Bronco - passanger side gone, still some grinding to do to make room for the radius arm mounts 1994 Ford Bronco - drivers side brackets. Also a decent shot of the top of a kingpin knuckle 1994 Ford Bronco - left to right, stock 35 spline inner for '87 kingpin, 35 spline yukon outer, 30 spline stock out 1994 Ford Bronco - 44 u joint compared to a 60. BIG difference 1994 Ford Bronco - left to right, 35 spline outer, dana 44 outer, 30 spline stock outer for 60 1994 Ford Bronco - brand new 35 on 15x10 next to a brand new 37 on a 17x9 1994 Ford Bronco - bigger, but not big enuf. really want the michelins or some 40's 1994 Ford Bronco - a shaved 14 bolt cover over a sterling rear for comparison. 1994 Ford Bronco - bye-bue POS 1994 Ford Bronco - I had the radius arms reinforced by a competent welder, not me. 1994 Ford Bronco - here are some comparison shots to a stock arm 1994 Ford Bronco - Three black steel bars or fork-like components, likely reinforced and freshly painted, stand upright in a workshop next to a Central Machin… 1994 Ford Bronco - Close-up of black-handled tools or tool grips with coiled red braided-cloth hoses in the background, dated 11.20.2003. A threaded metal rod… 1994 Ford Bronco - there is two ways to do a 60 with radius arms. 1. grind the wedges to fit or 2. use a spacer. i used a spacer i made from 3/4" stock to all… 1994 Ford Bronco - this is installed and ready for the lower coil mount 1994 Ford Bronco - before I put the spacer in, i tried to figure out the lower coil reatiner. thanks to Chris C. i made a pretty good one. i basically copied… 1994 Ford Bronco - Close-up of a black cast-iron differential or axle housing with a threaded steel puller/spreader tool bolted across it, using a large centr… 1994 Ford Bronco - Close-up of a heavy cast automotive component being worked on with a threaded rod/screw-type press or puller, secured by hex nuts. Part is… 1994 Ford Bronco - here is what Bill and i made 1994 Ford Bronco - installed with recessed 7/16 bolts for stock radius arm and cap with 5/8 for ttb retainer 1994 Ford Bronco - bracket with retainer and spring. it adds about 2" over the stock lower 79 reteiner I had with the 79. 1994 Ford Bronco - this holds the ttb coil much better than the 79 lower mount 1994 Ford Bronco - new lower shock mounts are done for now, till i do a shackle flip. that is a 6 ton jackstand for reference to the clearance i gained with 3… 1994 Ford Bronco - no more shock anchors to slow me down. the 10.25 is a big axle though. 40's would be very nice. I also bent all new brakelines, moving the… 1994 Ford Bronco - Had to clearance the 79 radius arm bracket on the drivers side to clear the driveshaft. the 88 dana 60's pumpkin is much further over than… 1994 Ford Bronco - the 60 is in, just waiting to finish the longer center link and track bar. Used the stock '79 D44 lines, and just hand bent them a little.… 1994 Ford Bronco - the whole front done. the spirngs are bowed in a little now, that could have been solved by putting the mounting bolts a little outward. if… 1994 Ford Bronco - closeup of pass side with lower trackbar mount (kinda) 1994 Ford Bronco - closer shot of trsckbsr/draglink angles. I used a stock ford, F350 steering arm as it is much beefier than the 1/2 ton ones, and has about… 1994 Ford Bronco - I used the 44 brakelines, and made this little bracket to attach to the breather bolt 1994 Ford Bronco - the new lower mounts raised the front a bit, and i definately have enuf room for the 37's and 40's should only require a little trimming. I… 1994 Ford Bronco - fullside shot with chessy/lab for rough height comparison 1994 Ford Bronco - I have a bit over 28" at the rockers 1994 Ford Bronco - Underside view of a vehicle's rear suspension showing a newly installed white shock absorber mounted vertically between the frame and the l… 1994 Ford Bronco - Close-up underbody shot showing a black axle housing with a U-bolt, leaf spring, and a large bolt securing a shock or track bar mount to th… 1994 Ford Bronco - 1" heims with 3/4 " bolts and spacers. the brackets were made to cover/use all holes made for all the rad arm brackets used to date. this w… 1994 Ford Bronco - drivers side extension. here you can see that there is a little extra space, it will be used for a cross member. the space between bolts wi…