Ricks Bronco: 1and 1/2

[rookieshooter]

Here is the perfect spill proof cup holder for you

Works like a gyroscope, made for rough waters on a boat.

http://www.basspro.com/BoatMates-Sw...uct/10202180/-1539345?cmCat=CROSSSELL_PRODUCT

That's exactly what I'm talkin about. I really need couple in the cab since the E-brake handles eliminated my little console that held my drinks.
The last few wheeling trips the Hot coffee was held between my legs...not a good thing on rough roads

I need to do my rear exo cage around fenders. I would like round tubing but since the fenders have sharp corners I was wondering how square tubing would look. Now I'm not talking about leaving the corners exposed and then butt welding another leg but a properly mitered corner like you see in a picture frame but not a 90 deg. Sure would be cheaper then DOM tubing and it would be strong with the square sides.
Plus there might be away of build a few steps off the square exo to get up into the bed so one could get into the seats instead of climbing up on tires. Especially since it looks like I might just go to a larger diameter tire and rim next year.

I posed a more involved question about the exo cage on the Off RoadThread.

 

[rookieshooter]

Decided on heavy wall square tubing. This will flow better with the angled fenders and also match the square tubing of the tire carrier.
Here it is just laying on fender. I'll have it just sticking out of the outside edge of the fender.
It's this part of the truck that I'm really worried about taking a hard hit. I have several sets of front fenders but this part of the body for me would be hard to repair.
Not ruling out the front, but done in a way that I can still remove fenders.

The top parallel tube I wanted at the point that the body protrudes out the most but done in a way that it connects to the roll cage for super strength.
Once welded up the air space around the part that penetrates the side will be filled with black RTV.
The other end will be welded to the 2x2" vertical piece of the tire carrier.

Here is the end that will be welded to the cage.

In my opinion the square exo compliments the square tire carrier. Now if the tire carrier was round then no way would I have done square.
Plus it was just laying around the shop...saved a bunch of $$

I'll turn the bottom tube so it's outside of the fender before welding up.
The outer most part of the exo at the part where the fender sticks out the most will have to structurally tied into the top part or penetrate the side of truck and then tied in.
May even run another fender hugging brace on the inside of the one going around the outside fender that would be flush with the side of the truck and going down the front and rear side of fender and then tie into the outside piece where both meet at the bottom.
Next I'll run some intermediate bracing between the two parallel pieces.
This should be strong enough to really smack a rock or tree and even to the point if it gets layed on it's side.
I did not want an exo where if it took a hard hit that the cage would flex into the body because of the way the cage was tied into the truck. That's my reasoning behind cutting thru the body and tieing in directly with the cage.
Everything else is tied into the cage why not this.

And another reason to get it done is the fact that I want ot repaint the truck all black. So this ought to be done before the painting starts.

 

[rookieshooter]

Maybe something along these lines as intermediate bracing.
Then paint black to match tire carrier.

 

[rookieshooter]

No rear armor.

About %90 percent done on the rear armor for this side.
Thinking of doing some triangulation supports from the bottom tube to the top tube. This will transfer a hard hit to the outside of the fender to the above tube also.
Going with the mitered square tubing kept all the bends close to body and fender flair.
I'll also close up the end at bumper and RTV where it penetrates the side.

 

[rookieshooter]

Think I'm going to go with this design, it should be structurally sound.
Thinking of adding those little steps, this will make it easier to get into the bed.

Then encounters like this won't matter anymore.

Had to do some more testing on the seats. This is the same hill that I did a vid of a couple pages back. Did not want to hit the brakes too hard going down, especially if the front grabbed a little too hard then the back wants to come over.
Seats did well and so did the passengers , just kidding.
Main reason is that I'm still learning the ins and outs of the Aussie/Atlas combo...I'm just such a slow learner.

In fact one of the places I'll be Spring Turkey hunting is where that pic was taken. Hmm might just be to do a little wheeling after early morning hunting.
Killing two birds with one stone type thing.
No Hunting after Noon anyway.

 

[rookieshooter]

Starting to look like the side of a Sherman tank.
Keeping with the square tubing theme. The intermediate bracing is square solid rod. It's built along the lines of structural steel bar joists that can handle extreme force.
I had to build the sheet metal flares out far enough to pass inspection so this puts part of the exo well past the body. So that called for more bracing to counter act the leverage that could be put on it by rocks, trees, deer and the side of my garage door ha ha.
Plus it ought to make for a good step once you climb up on tire. Have not tried it yet but some small foot pads maybe added.

Still have to do some minor things to it.
But I guarantee one thing I will bounce of some rocks and trees to proof test it.

I'll slap some paint on it next, this east coast humidity with day after day of rain is getting old and any unprotected metal rusts up quick.

 

[janderson4010]

Starting to look like the side of a Sherman tank.

I'm gonna say more like a rig out of mad max,

Like the sign says, "speed's just a question of money. How fast you wanna go?"

haha awesome, paint it all completely black and mount a machine gun on the roof, actually i believe there was talk of that a few posts back... kinda

 

[rookieshooter]

And once it's painted all black it will look like one of those apocalyptic buggies LOL
Received my rebuild parts for the broken Fox Coilover.
The 5/8 shaft is in the large plastic bag. The bottle has the shock oil.
I like the way Polyperformance kept in touch while it was on backorder.

Now just need to put it all back together.

 

[Nick26]

haha, You spent all that time lightening it and now your adding weight back to it! Are you really worried about the body on it anymore anyway?

 

[rookieshooter]

haha, You spent all that time lightening it and now your adding weight back to it! Are you really worried about the body on it anymore anyway?

Bottom line...As it becomes more trail worthy and less driven on the street the more it changes due to the circumstances.
Now thinking of some Chromo axles, first the front.

 

[rookieshooter]

Taking the valve body off the broken coilover shaft.

There are two assemblies of these stacked washers so be careful that if you take them off that they go back on in a the same order.

Torquing the nut to 30#s after rebuilding the valve body.

Next I put in new 5 wt oil that I got from Polyperformance. For this shock it called for it to be filled 3.5" from end of tube.

Then install the new shaft with the valve body pushed far enough down in the tube so the snap ring can be installed in the groove.
Next is to install the round bearing retainer that seals the bottom and that's it.
Other then pressurizing the shock with nitrogen.

 

[janderson4010]

you been to busy out wheelin to post up or what?

 

[rookieshooter]

you been to busy out wheelin to post up or what?

Just like in Deer season I don't do much posting cause I'm getting up around 3:30 and out wheeling the hills with all those cool off-road lights on getting me thru those dark back roads.
Well now It's Spring Turkey season which I like even more then Deer season.
I've been getting up around 3:30 each morning and for the last 2 weeks and I'm just so tired. Climbing these hills each morning before light takes it toll on me anymore.
I'm also taking videos each morning. You can see some here.
http://www.explorerforum.com/forums/showthread.php?t=314956
I also guide for other hunters trying to call in one of these Old Toms.
Where you see the pick is one of the farms that I hunt. Plus it's just so fun actually using the lockers, new tires getting thru all the wet muddy trails.

In about a week I'll make the matching side armor like I did the one side. Also since I've changed the way the cab roll cage is designed, I'm going to make new tubed doors that I can install once the real lightweight doors are removed. That's if the weather ever gets warmer. May go with the same square tube design as the exo. That way it all matches.

See ya getting up in 5 hours.

 

[1996X]

Love what you have done to the bronco. I like the idea of the rear seats for passengers. I always come read your post when I get bored on the other sites im on. haha

 

[janderson4010]

we should put a sticky on the forum, West Virginia hunting seasons, that way we all know where the heck you got of to... lmao

 

[rookieshooter]

we should put a sticky on the forum, West Virginia hunting seasons, that way we all know where the heck you got of to... lmao

My wife feels about the same way. She put this on the walls years ago.
She even got me a cell phone to take with me...Seems that in some mysterious way it's always on Silence all this time of the year, especially Spring & Fall.
Must be some kind of geographical oddity with all the mountainous terrain around here.

 

[janderson4010]

well in the mountains around here i just flat don't get reception, crazy thing

 

[rookieshooter]

Went and picked up 24' of square tubing to finish the other body armor for driver side rear. This will be way more then I need, but I'm sure I'll come up with some idea.

Here's how I come up with an exact cut for the angles. I use some cardboard that's about the same size and lay at the same angle.
One is over lapped the other. Then I mark where they intersect top and bottom Vs. Then draw a line from dot to dot on piece of card board.

Then cut along line and place the template on the cut off saw and move the angle gauge so wheel cuts that exact angle.

Then tack up and test for fit. When done the tubing will over hang the fender.

 

[rookieshooter]

Almost have the bottom tube done. Just have to weld up the two ends...one at the slider and other at bumper.

Dremel tool works great for the penetrating the side of the truck for the top tube.
Just like the other side, this hole is cut so the top tube turns 90 deg. and fastens to the cage.
Then just like the other side the bottom tube will connect to the top with some intermediate bracing.

On another note, my friend Gene brought down his orbital sander and told me don't bring it back untill this thing is all black.

Well I told him it may be a month of or so. I guess I leave some hardcore 4x4 parts that I wanted for a later date and get this thing painted while the weather is turning nice. That's another reason I'm doing the exo now instead of after it's painted.

Been out Spring Turkey hunting for a little over 2 weeks now with out missing a day.
What a difference riding all these up and down hill muddy trails with all the rain we've had with the rear locked and the Aussie front locker. Last year this time I would be slipping all over the place.

May also start on redoing the tubed doors tomorrow.

 

[rookieshooter]

Now working on the top tube.

Fitting up.

Now to go get some 1/2 x 1/2" solid rod for the vertical braces that will tie both top and bottom together.

Now even the back has complete wrap around protection including brake light housings.

Plus the metal that I added including tire gate less tire still don't weigh as much as the B2 hatch back I took off and it's all below shoulder height where as the hatch back went up to the roof...what roof ha ha. Plus those fiberglass seats in the rear are just a few pounds apiece compared to the stock overly heavy rear seats that were in there. But the added rear weight coupled with the 103" wheel base makes for a better ride then it ever had and it's a no brainer how well it does on the climbs.
As far as this truck is concerned. Can't speak for others though.

Just checked out next weeks weather more rain and then more rain. That equates to locked front hubs and Atlas in 4 high while doing those trails again next week.