View Full Version : BigNorm

July 12th, 2005, 09:19 AM
HI all. I was referred here by Dr. Smash out of Carson City. I reside in Dayton, NV and my obsession is wheeling and working on my 86 Bronco. I've extended it's wheelbase 7.5": 3" in the front and 4.5 in the rear using rear Bronco leafs both front and rear. I'm running a Welded 88 Ford D60 up front and a 10.5" 14 bolt off of an 80s 3/4 Ton Chevy in the rear. It's got a Detroit locker. It's currently got 4.10s on 38" tires. I know this sucks but I slapped it together this way because I have gone too long without wheeling it. (I've been putting it together for the last year and a half). The drivetrain consists of a 351W, C6, NP208. It's been alot of work and I did it all my self. I look forward to wheeling the hell out of it the rest of this summer.
If you would like to see more pics of my Bronco they can be found at my superford (http://www.superford.org/vehicles/registry/detail.php?id=2538&s=26858#content) link. Take Care. I'm glad I finally found a local board. NORM

July 12th, 2005, 09:40 AM
welcome! enjoy your stay. :gapteeth: :rock:

July 12th, 2005, 03:30 PM
Makes me want to sell my jeep and supe up my blazer ><

July 12th, 2005, 05:16 PM
Fully Getting It Big Norm!!!!! It,s Always Nice To Get In Your Rig On A Nice Summer Day Wether It Be After Work Or On The Weekend And Go Play. Even If There Are No Rocks Involved, Just A Nice Stroll Thru The Desert Is Good Too.

Dr Smash
July 12th, 2005, 08:35 PM
hey NORM glad to see you found your way here Welcome!

July 12th, 2005, 11:17 PM
that's a nice bronco hope to meet ya some time

July 13th, 2005, 11:43 AM
Thanx for the kudos guys. I've been working the bugs out one by one. (Did you know the carb doesn't like to have a vacuum source hooked to another vac on the manifold?) :lolrun: It's been a long trial. It is nice just to cruise down any old dirt road thats near me.

July 13th, 2005, 01:53 PM
Is that as far as you made it up that dune? Gotta love big rigs and sand eh?

July 13th, 2005, 08:53 PM
No. I just stopped there for the pic. This hill seems to like a little momentum, second gear (low), and hammer down. :D I'm loving the hell out of the welded front. I was skeptical of it because of all the steering problems I've heard. In dirt and sand with my Saginaw pump it turns the 38s with no problems. A ladder bar setup is definately coming soon to deal with the rear axlewrap.

July 13th, 2005, 11:28 PM
Welded the front spider gears? I bet thats fun on the street :)

Makes me want to put a 9" lift on my blazer, 38" boggers, mpfi kit.

Dirty Harry
July 14th, 2005, 06:03 AM
Welded the front spider gears? I bet thats fun on the street :)

Some rigs have hubs that you can unlock. :disagree:

July 14th, 2005, 08:06 AM
Welded the front spider gears?
The guy who welded this went way beyond the spider gears

I bet thats fun on the street
No it's not fun on the street. That's when I have to get out and unlock the hubs. I've only been seriously testing my truck for the last 2 weeks and I absolutely love the gain in traction. I went welded because of monetary concerns and I got a good deal on the diff and gears. I built this truck as my wheeler/camping rig. I've got more junk to haul to my remote locations than I can list. I'll just say that when set up my wife and I are real comfy. Who cruises in 4wd on the street anyway? In the snow I plan on just locking one side. It's not ideal but it's what I've got. Anyone who has an ARB they want to give me is more than welcome to it. :D

Makes me want to put a 9" lift on my blazer, 38" boggers, mpfi kit.
Make sure you scrap your POS 10 bolts and replace them with the propper One Ton units. You can also get away with less lift by cutting and/or extending the wheelbase.

September 22nd, 2005, 10:15 AM
Deer Valley Trail 9/10/2005:



September 26th, 2005, 11:41 PM
Man you should go down to shaffers and check out the green bronco they just got done with they put coilovers on the front and Y-linked the rear, heard it scored pretty damn good on the ramp to :D

September 27th, 2005, 06:47 AM
Sounds like a cool setup. I've known more guys to have gone from coilovers to leafs than I have leafs to coilovers. It's a reliability thing. I'm proud to have done this pretty much on the cheap with mostly stock parts.

Samco Fab
September 27th, 2005, 08:33 AM
Nice Bronco,thats a pretty bulletproof setup. What does that put your wheelbase at, about 114?? I would get rocker pannel protection sooner than later, I made that mistake on my Bronco and wasted the sheetmetal pretty quickly.
How strong are those 208 Tcases, I know they are alum. and chain driven. That might be your weak spot in your drivetrain. I have a Ford 205 if you are interested.

September 27th, 2005, 03:17 PM
Thanks for the compliment. I believe my wheelbase is around 112". That's judging off of if a stock bronco is 105" I can't remember if it's 105 or 107. If it's 107 then you'd be pretty close at 114.5" I stretched it 3" up front and 4.5" in the rear.

I've got 3x3 square tube bolted to the bottom of my quaters. I'd like some full out sliders like you're talking about eventually to help slide around boulders. Especially with the extra wheelbase and bigger tires.

I know the NP208 is a weak point but it's what I've got at the moment. I plan on doing a NP203/205 doubler in the future. I may be interested in the 205 for that project if the price is right. It's still aways down my list of things to do.

I did my whole rig as inexpensively as I could. I know a few guys who've gone with stock rear leafs up front but most went with lift leafs in the rear. Mine are still stock which makes for great flex but I'm thinking at a small loss of sidehill stability and clearance between the shackle and the ground. I didn't even have my D60 when I started putting together my front xmember. I just went off of information I acquired from a guy named Keith L. One of the big name guys in the fullsizebronco.com forumns. He's popular for coming up with a pretty reliable SAS with F350 leafs and rearward mounted shackles.

Here's a list of things I still plan to do:
5.13s (4.11s on 38s suck but hey, I use what I've got)
fuel injection (I'm still not sure if I'll be going Ford or Chevy TBI)
35 spline outers
Dedenbear knuckles
hydro assist steering
44/19.5r15 boggers (I'm totally infatuated with this tire. But I want to make sure it's built for them before I go there)

Any other suggestions you can think of would be greatly appreciated. My build generally goes slow but I do make progress one small step at a time. :)
Thanks again! NORM

October 15th, 2005, 10:37 AM
After having my original Warn 8000 for years I finally got around to making it work on my truck. (When I had it mounted before I accidently broke the power bolt and had to have it taken off to be rebuilt) Anywho. I've made a receiver hitch for the front and mounted a receiver on the mount. I don't think it looks half bad:

October 15th, 2005, 11:12 AM
Looks Good on your truck. might look weird on a smaller vehicle but it fits with your bronco :yes:

October 15th, 2005, 11:45 AM
Looks Good on your truck. might look weird on a smaller vehicle but it fits with your bronco :yes:
Thanx. We'll see how good/ bad it looks when I get around to making the front bumper for the xj. I'll be putting a receiver on it also. It'll be cool to be able to swap it back and forth. Since my xj is my commuter the winch will probably see more time on it.

February 3rd, 2006, 06:24 AM
I just wanted to post up here with what came of my add a leaf or two project.

Ok Here's what I came up with. Here's my before measurement:

I took the 2nd and 3rd leaf from the top of an F150 leaf pack. When I bought this pack I didn't know that some of the newer year of Ford trucks came with 2.5" leafs. I got both packs for like $35 and they were unrefundable so I went and used them in conjunction with my 3" pack that came on the Bronco. These leafs are also slightly thinner than the bronco pack.

You can see the leafs I added. I put one of the F150 leafs dirrectly under the stock main leaf. The other one is 4 leafs down from the top. I now have a 7 leaf pack and no 2" spacer. I didn't use the overload leaf from the F150 because there would have been interfereance with the stock strap which I hammered flat and then bent them around the pack again the best I could to keep the leafs from wandering too much.

Here's the after picture before I took it on the break in drive:
It looks like I gained rounghly 2" before the pack has had a chance to settle. So when you take into effect that I removed my 2" blocks then in using the two leafs off the F150 (87+ body style) I essentially gained 4" when using it in the shackle flip configuration. I'm thinking it would be slightly more if it was still on stock hangers because the leafs hang more at an angle that a shackle flip does which runs flat.

I'm happy with the results so far. I don't lean outwards near as much during street cornering and offroad my stability feels much better. I felt much more comfortable side hilling and I found that as hard as I hammered down on the stupid peddle in the soft stuff I could not get the rear end to bounce so this may have eliminated my need for a traction bar as well. Does it flex? I'm still satisfied:
I still need to install bumpstops up front. I've measured roughly about 6-7" of compression at the front leafs which makes the main leaf twist like crazy which according to what others have told me is only a matter of time before I snap one. I'm thining of limiting the compression to 5" up front. This would give me about 8 inches of total suspension travel still at the shocks as it only droops like around 3" at the shock. I'm much more happy with sidehilling. I can still feel how soft the front is but it doesn't feel near as floppy as it did prior to removing the blocks and adding the two leafs. I'd definately recomend this for anyone looking to get around 4-6" of rear lift without the use of blocks.

February 25th, 2006, 08:16 AM
The first thing I did was place the rear hanger. I did this so I could better set my shackle angle when positioning the front hanger. I modified the hanger by cutting material off the bottom because it appeared I was going to hit my shackle when mounted in the front hole. I turns out that I ended up using the rearward hole anyway. Oh well. live and learn. It still may prove helpfull in the future if I ever decide to go with longer shackles and use the front hole. If you look close you can see I've done this shackle flip 3 times now. lol
I then placed the front hanger. Notice that I had to drill a center hole. The reason for this is that there is not enough clearance for the leaf in the front and rear holes, it rubs. Had I known this when I ordered the shackles I would have specifically asked Sky to center drill the hanger with a 5/8s hole. Drilling holes this big with a dull bit sucks. Start small.
It appears that I've yet again extended my wheelbase. With my current leaf setup (stock bronco leafs w/ 2 F150 leafs added) it appears I'll clear the tank just fine.
What's your guys oppinion on the driveline? I'm thinking I may have to get it lengthened. It stays around the same length under droop because of the shackle movement.
It now appears the front is slightly taller again. I'm considering redrilling the holes in the front hangers higher up. I'll also be adding an F350 main leaf. I'm not too sure what that will do to the ride height or how many leafs I'll be going with so time will tell.

February 25th, 2006, 05:14 PM
I would probably lengthen the drive shaft some. I recently made some changes to my crossmember and my driveshaft looks about the same as yours. Mine also only travels about 3/4", from stuff to droop. So far it has worked, through Fordyce, and the Con, but I want some more length for piece of mind.

If you haven't cured your rear spring wrap I would really be concerned about that shaft coming apart. Lookin good Norm, can't wait to wheel with ya.


February 25th, 2006, 06:17 PM
Rear spring wrap hasn't been a problem since I added the 2 F150 leafs. I'll probably have another shaft made and use this one as a spare. But till then I'll probably wheel it like you've been doing. I try to be light on the skinny peddle as much as possible.

March 4th, 2006, 08:56 AM
I finally got my front main leafs replaced. I still have to make some clamps so hopefully I don't bend these again. I'd think it would be harder this time since I used F350 main leafs. The rest of the pack is the stock Bronco rear leafs and I removed the overload leaf.
5.13s will be added soon. I can't wait. But then I'm like that with every modification I do. Take Care! NORM :D

March 4th, 2006, 12:31 PM

August 6th, 2006, 11:42 AM
I haven't updated this for awhile so I thought I'd post a few pics
I got rid of the tailgate, top, built a bulkhead, mounted a truck box and mounted the battery behind the bulkhead.
Currently I'm narrowing the front. I'm hoping to have it finished soon. I need one more day I think. I'll be working on half doors next, real sliders and exoing the front clip.

October 5th, 2006, 08:05 AM
And most recently I discovered I was hitting my Tie Rod and Drag link on the frame. This resulted in a bent TRE the last time out. Which is bad. My solution was to install some bumpstops which I pulled off of an Issuzu Trooper. So far they've been great!
Also installed in these pics is a larger Tie Rod as I needed a longer one to go with my shorter end on the Passenger side.

72 Virginians
October 5th, 2006, 08:32 AM
Did you swap the t-case yet?

October 5th, 2006, 09:34 AM
Not yet. I was going to do it today but tomorow is half price day at pick n pull. I'm going to collect and bury my plunder today and pick it up tomorow morning as to avoid the rush. I'm sure several have the same idea. I may get it in tomorow. If not, definately next week. I've heard it's really easy to swap out cases of the same type but as I haven't done it before I want to give myself some time. I've asked around and the consensus is that I probably broke the high range shift fork. Apparantly theres one for the hi and one for the low. Good thing or I probably would have been stuck stationary. We need to find more Fool Sizes to go along so that we can tow each other back home if need be. :knokwood:

November 25th, 2006, 06:25 PM
I spent the day at Eric's shop and am very happy with the sliders he fabb'd up for me. Here's some pics on the ramp after we got done.

The sliders are mounted to the frame via 4 pieces of tube on each side and it is connected dirrectly to the cage. Now it sounds even more like a tank! :D

November 25th, 2006, 08:35 PM
Sweet!!! I like the way they are angled out! Makes them look less boxy.

November 25th, 2006, 10:34 PM
That was thanks to Eric. I went there thinking that's how they were going to be done. He explained what he had planned and I agreed with the idea. They are narrower towards the front and flared out a little in the rear. I'm really happy on how they turned out. :thumbsup:

72 Virginians
November 25th, 2006, 10:47 PM
Looks good Norm. :thumbsup:

Hope to see some action pics next week.

Dr Smash
November 25th, 2006, 10:51 PM
Thanx for the business Norm!

November 25th, 2006, 10:55 PM
Thanx for the business Norm!

Thanx for letting me hang out!

Looks good Norm.

Hope to see some action pics next week.

Definately :gapteeth:

December 28th, 2006, 05:24 PM
Here's the latest:

130A G3 alternator pulled from a Mercury Sable. The pully swapped right out with the stock G1 alternator that I started with and fit's like it was made to go there. Very cool. I was expecting to have to do some backyard machining to make it work.

I'm also installing duel electric fans pulled from a Ford Aerostar I believe. I'm going to be lowering the radiator support so the hood can droop more for better visability. This is How low the hood should hang when I'm done.

January 3rd, 2007, 07:11 PM

January 7th, 2007, 07:03 AM
are you leaving the shrowd on ? why?

January 7th, 2007, 06:58 PM
When I ran an electric fan on my mustang way back when it was overheating. I tried it with the stock shroud and got a ton more vacuum out of it. I plan to try it both ways and see what works best. I've got like an inch between the electric fan and the radiator. All that holds the shroud on is two bolts. I'll try it in both configurations (with and without the stock shroud) and figure out which works best. If there is no noticable difference I may or may not leave it on. I think it's cool I made it work. :D

Reno Off-Road
January 8th, 2007, 02:08 PM

Is this that sandpit at the track right before you get to Pyramid Lake?

January 8th, 2007, 06:02 PM

Is this that sandpit at the track right before you get to Pyramid Lake?[/QUOTE]

No it's actually only a couple minutes from my house. It's cool to test stuff out on. I had better enjoy it while I can it seems everything out hear is being built on. They're saying Wall Mart is coming soon.

January 8th, 2007, 06:05 PM
They're saying Wall Mart is coming soon.

Doing BIG things eh norm? :thumbsup:

January 8th, 2007, 07:24 PM
Dayton is growing like a weed. Fast. I love living in the middle of nowhere. The wife requires to be close to civilization. oh well. :(

Here's as of today. I got a pretty good gash in my cheek when the hood fell on my head and I cut it on the radiator support when was getting the radiator put in. I'm kinda upset I lost so much time going to the emergency care but I thought I'd better take care of my mug for my wifes sake. :)



January 9th, 2007, 09:33 AM

January 9th, 2007, 10:22 AM
Here's as of today. I got a pretty good gash in my cheek when the hood fell on my head and I cut it on the radiator support when was getting the radiator put in. I'm kinda upset I lost so much time going to the emergency care but I thought I'd better take care of my mug for my wifes sake. :)

any pics of your gash?:D

January 9th, 2007, 03:15 PM
Nope. I wasn't too worried about pics. I did change before going to the urgent care though.

February 20th, 2007, 04:55 PM


February 20th, 2007, 05:06 PM
So does this mean you are ready to go do some wheelin. :cool:

February 20th, 2007, 05:24 PM
Almost. As you can see in the pic I need to make a bracket to hold my radiator overflow/washer fluid container. I have to secure the wiring and figure out why the lights electronics isn't working, turn signals, and I'm sure I've forgotten something. The electric fans work great and the view over the hood is awsome. I gained a bunch of visibility.

February 27th, 2007, 06:18 PM

72 Virginians
February 27th, 2007, 07:55 PM
I like the new look. :thumbsup:

February 27th, 2007, 08:03 PM
For sure looks good: cool: So you just got to do some wiring?

February 27th, 2007, 08:47 PM
Love teh stinger bumper :thumbsup:

February 27th, 2007, 08:49 PM
Lookin good!

Dr Smash
February 27th, 2007, 09:13 PM
Those wire shelves made a great grill! looks great Norm!

March 14th, 2007, 03:35 PM
Almost ready Mark!


Sierra Valley
March 14th, 2007, 03:43 PM
Looks good norm

What tires and axles are your running?

March 14th, 2007, 03:48 PM
Thanks again for the rims Norm!

Looks good. Those the new tires you wanted?

March 14th, 2007, 03:58 PM
Looks good norm

What tires and axles are your running?

Those are 39.5x15.5r15s on Allied beadlocks. I'm running a D60 front Welded
With stock axles. I want to to swap up to 35 splne chromo outers soon but I currently have a spare set of trail spares with the stock 30spline outers so I'll see what happens for a bit and take it slow (hopefully. lol))

I'm running a 14 bolt rear with a detroit. Nuff said there. :D 5.13 gearing in both.

The rest of the drivetrain is a 351W, C6, and NP208. I'll get to the 203/205 doubler eventually but it looks like I'll do a rear narrowing project and see if it'll hold all summer. :)

Yeah Don. Those be them! :gapteeth:

Sierra Valley
March 14th, 2007, 04:01 PM
Sweet looks ready for some rocks:D

March 14th, 2007, 04:04 PM
The new wheels and tires look great Norm, So maybe in about a week and a 1/2 I had to get a CV joint for the rear driveline will not be ready intil middle of next week.

72 Virginians
March 14th, 2007, 06:11 PM
Looks good Norm. :thumbsup:

Dr Smash
March 15th, 2007, 10:24 PM
Those tires look just right norm. Gotta make room in the rear for them sucka's

March 19th, 2007, 06:33 PM
Work, work, work. While I love wrenching on the hunka junk there comes a time where I must PLAY! Which I think is what this wheeling thing is all about anyway. Here's some pics. Everything worked great other than my windshield wants to detach. Not very enlightening. I better carry some goggles in case it decides to go eventually. Here's the pics.


72 Virginians
March 19th, 2007, 07:06 PM
Sweet :thumbsup:

March 19th, 2007, 07:33 PM
That fawker looks mean!

March 20th, 2007, 07:46 PM
that was fun today.
sorry about the over heating.
you should get a o sh:t buzzer on that temp gauge.:blender::
and a big gas resivoir for those long hill climbs:rock:

Fish Sticks
March 20th, 2007, 08:02 PM
Looks like its working great Norm. I went on the El Do run you organized last fall......how 'bout organizing a sand run in your dunes before it gets to hot.....probably have a big turn out, real big.

March 20th, 2007, 08:44 PM
There's no dunes. Just a little dirt near where I live.

Dammit Werty. Quit postin' up all the shortcomings. I shut the fans off to get it started again. I think an electric pump and a regulator would keep that from happening again. I think the incline put too much strain on the mechanical pump. It crawled right up though.

March 20th, 2007, 08:59 PM
[QUOTE=BigNorm;88402]Work, work, work. While I love wrenching on the hunka junk there comes a time where I must PLAY! Which I think is what this wheeling thing is all about anyway. Here's some pics. Everything worked great other than my windshield wants to detach. Not very enlightening. I better carry some goggles in case it decides to go eventually. Here's the pics.

one of my budies has the same bronco and he has the same flex in the body. the main part of the cab is acually spliting at the factory spot welds. looked for a pic but i cant find it. sweet bronco!! i love the fornt end.

March 21st, 2007, 05:46 AM
There's no dunes. Just a little dirt near where I live.

Dammit Werty. Quit postin' up all the shortcomings. I shut the fans off to get it started again. I think an electric pump and a regulator would keep that from happening again. I think the incline put too much strain on the mechanical pump. It crawled right up though.

:D o and did i say that i killed the battery on jens mitso and now my truck :idea: :scratch: I think batterys dont like me.

April 24th, 2007, 08:42 PM
Well here's the last run's dammage for those who didn't read I wish I had a Dr Smash leaf spring patch:


Here's where it broke:

Here's what I did: Superduty main leafs with F350 pack

I finally got it all together today. These stupid duty leafs have some humongoid droop going on. something I didn't have going on before. It's a little stink buggish but I think the leafs will settle some more in time. There isn't really anywhere to place the clamps. I used the superduty main leafs I was given with 69 F350 leaf packs under neath (also free I had laying around). I think I'm going to try and find the point where the leaf pack gets flat and bumpstop it there to try and prevent a repeat performance. I have to redo my shock mounts up front since it appears I've moved the front end forward about an inch. Superduty mains have the hole much closer to the front compared to a regular F series. It's kind of funny. I had to move my rear hangers back, My front hanger hangs inboard more than before and I still gained an inch in front. Who'd a thunk?

I'll post up pics tomorow.

April 25th, 2007, 06:30 PM
Superduty main leaf with F350 pack

Stock bronco pack with two added F150 leafs (for comparison)

April 25th, 2007, 06:56 PM
You going to move the shock mounts?

April 25th, 2007, 07:40 PM
we off road just about every weekend just check out this site and see the dates. there is a trip going to hunter lake this saturday.

April 25th, 2007, 09:06 PM
You going to move the shock mounts?

I've got to. Hopefully I'll get it done in the next couple days.

Thanx for the invite SideEye. Unfortunately my job requires I work weekends. Evil never sleeps. lol.

Dr Smash
April 25th, 2007, 09:14 PM
looks good Norm glad I could help.

April 25th, 2007, 09:27 PM
You are the man Eric! a thousand thank yous! :thumbsup:

Dr Smash
April 27th, 2007, 09:37 PM
norms new draglink and a few pics

72 Virginians
April 28th, 2007, 08:47 AM
Sweet :gapteeth:

May 1st, 2007, 07:21 PM
Well I'd say we should go wheeling but you would spend 90% of the time pulling me out.

May 1st, 2007, 07:36 PM
I killed the leafs. The shackles inverted on themselves and I ended up tweaking the leafs beyond repair. I also busted a 1410 yoke because it was hanging so low after the leafs tweaked. Back to the drawing board. It looks like I'll be using Arch's leafs when I can get them. I'm really really considering starting work on a buggie from the ground up. But I want to remain wheelable in the mean time. I think I'm gonna finally take some trips with my Quad.

Dr Smash
May 1st, 2007, 09:24 PM
Norm that sucks right there. Sorry bro.

May 2nd, 2007, 04:17 AM
Well I definately learned something about different spring rates and shackle angle. I feel bad about bending the leafs you gave me. This next time I plan on having alot of shackle angle. I'll probably have you make me some shackles as well.

June 19th, 2007, 03:53 PM
Norm, hon, you need to update this :D ;)