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Leaf SAS Project

From 1986 Ford Bronco “Old Desert Goat”, documented by BigNorm.

49 photos
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1986 Ford Bronco - Here you can see I notched the frame and installed two sections of 3x4x1/4" steel tube to extend my frame by 4" 1986 Ford Bronco - front view 1986 Ford Bronco - I purchased a 40" of 5x5 angle iron. the frame rails on the truck are 40" from outer to outer frame rail. 1986 Ford Bronco - I made the hangers out of two pieces of the 3x4. I cut the pieces to 5" with a cutting wheel, drilled it with out to 5/8ths, cut the bottom… 1986 Ford Bronco - Here's a front view 1986 Ford Bronco - Welded to the frame, Gussetted for lateral support, D rings for winch/chain anchors 1986 Ford Bronco - front view 1986 Ford Bronco - F350's are in short supply in my wrecking yards and when found the yards think they are made of gold. The hangers are parts for a 1990 F350… 1986 Ford Bronco - Underbody view of a vehicle supported dangerously on a stack of concrete cinder blocks topped by an orange jack stand, with the leaf spring… 1986 Ford Bronco - Here's a mock up of how I think things will line up. I just hung the body clip on and set the tire where the center pin is at. With the axe… 1986 Ford Bronco - A blue two-tone 1980s Ford Bronco viewed from the 3/4 front, mid-teardown with the front clip and engine bay stripped, showing the bare fra… 1986 Ford Bronco - Is it just me or does this leaf angle look alot better than when the shackle was to the rear. I probably could have figured this out if I w… 1986 Ford Bronco - Underside view of a vehicle frame supported on stacked concrete pavers and an orange jack stand, with a curved leaf spring visible and vari… 1986 Ford Bronco - Here it is at home in my yard at long last. 1986 Ford Bronco - I got 4 8 lug rollers from a local yard to hold the project up. I figured it would be a hell of alot easier to manuever the beast this way. 1986 Ford Bronco - Here's a picture of it under the truck with the vehicles weight on it. 1986 Ford Bronco - You can see in the picture here that I won't be using the drop pitman arm. It appears that I'm going to have to use a highsteer arm for the… 1986 Ford Bronco - Here's my grind work on the drivers side. I've been told all I have to do is notch it so this should be sufficient. I'll be using a 4" bent… 1986 Ford Bronco - These are the two Ubolt plates I used. The one on the right is off of a 10.25 rear off of a F250. The one on the right is off of a 9" rear. 1986 Ford Bronco - You can see on the 10.25 ubolt plate that I had to "feather" out the holes for a 4" Ubolt to fit near the diff on the drivers side. 1986 Ford Bronco - Close-up of a freshly painted blue front axle and leaf spring suspension under a vehicle, viewed from the side near the tire. The setup res… 1986 Ford Bronco - Low-angle underside view of a front axle painted blue, showing the differential housing, tie rod, and steering knuckle, with a large off-ro… 1986 Ford Bronco - Close-up of a freshly painted blue cast-iron component, likely a differential or steering/suspension bracket, secured with four large bolts… 1986 Ford Bronco - The Ubolts I used for this initial mock up are two 3 1/4" ubolts on the 9" plate. A 4" and a 3 1/2" plate were used on the drivers side. Se… 1986 Ford Bronco - Front view of a bare truck chassis with a freshly painted blue front axle and leaf springs, mounted on chunky off-road tires. A rusty frame… 1986 Ford Bronco - Alas I had managed to move my axle too far forward. Under compression (Me bouncing up and down on the front end) I discovered that the Pitm… 1986 Ford Bronco - A partially disassembled two-tone gray/silver SUV sits on gravel with its front end stripped, engine and wiring harness exposed and the fro… 1986 Ford Bronco - I have to cut 3" from the square tube I used in order to move it in more. 1986 Ford Bronco - I also needed to notch the frame some more in order to fit the hangers on the angle iron. 1986 Ford Bronco - Close-up of a rear suspension undergoing service, showing a rusty leaf spring and shackle mount, a blue axle/frame member, and the tire sup… 1986 Ford Bronco - How'd you like to be woke up by this guy? heh heh heh 1986 Ford Bronco - Here's my xmember and hanger assy with my tubes chopped 3 inches shorter 1986 Ford Bronco - Here it is mocked up. I have to do a little more grinding on this side but other than that every thing is going according to plan. 1986 Ford Bronco - Here is my drag link after taking 3" off the front and moving the Hanger 4" back 1986 Ford Bronco - A partially disassembled vehicle chassis viewed from the front-left, with the front bodywork removed exposing the engine, wiring, and frame… 1986 Ford Bronco - Here is the new location of my rear leaf hangers. Since I had already cut the stock F350 hangers to fit the way they were before I simply c… 1986 Ford Bronco - boxed 1986 Ford Bronco - Close-up of a freshly blue-painted, heavily welded steel bracket or mount fabricated onto a vehicle frame, with a cast component and drivel… 1986 Ford Bronco - Close-up of a freshly painted blue steel frame section and rear leaf-spring suspension on a partially disassembled truck chassis, with a ba… 1986 Ford Bronco - A partially disassembled vehicle chassis with a freshly painted blue front frame section and axle, mounted on white steel wheels with worn… 1986 Ford Bronco - Po mans locker! Lincoln welded to the max! That pin aint breakin. It's all a solid unit now. 1986 Ford Bronco - A dark blue/black Ford full-size SUV sits on jack stands in a gravel backyard with the front end partially disassembled, front axle and sus… 1986 Ford Bronco - Here's what I came up with for lower shock mounts. This problem has plagued me for months and this is my solution. I used 3/8s angle iron a… 1986 Ford Bronco - Underside view of a vehicle showing a newly installed white shock absorber mounted to blue-painted leaf spring components and a frame rail.… 1986 Ford Bronco - Underside view of a vehicle's front suspension showing a white steering damper/stabilizer mounted vertically, connected to blue-painted axl… 1986 Ford Bronco - Low front-end shot of a lifted truck showing the front axle, leaf spring suspension, steering linkage, and a large mud-terrain tire. An amb… 1986 Ford Bronco - Underbody view of a blue-painted front axle and leaf-spring suspension, showing the differential housing, a leaf spring pack, steering link… 1986 Ford Bronco - The driveline angle looks good. 1986 Ford Bronco - Front view of my tranny xmember