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My new sexy Bronco


Slipknotyk

Active Member
Joined
Dec 9, 2009
Messages
26
City
Denver
Vehicle Year
1997
Transmission
Automatic
I recently bought a 1992 Ford Bronco from a local auto auction. For $1100, she was quite the steal.
She's an XLT with leather, 5.8 V8, E4OD, 4x4. Everything works for the most part. There are little things, like the driver side power window switch won't roll down the passenger side. 195K miles

This is her the day I got her back from the dealer. 2-13-13
IMAG0074_zpsd29ea323.jpg

IMAG0073_zpsc8660545.jpg

IMAG0080_zpsaa3fd43b.jpg

IMAG0077_zps92639425.jpg


This is under her hood. She's dusty, got a small bit of oil, all is fairly typical.
BroncEngine_zps606bc084.jpg

A little bit of tampering by former owners left this nice little bird's nest of wiring. At least this one isn't too terribly bad :icon_twisted:
BroncEngine2_zpsa9f55bd5.jpg


So, here's where she stands.
195,3XX miles at purchase

Major repairs needed:
  1. Tires
    Old tires are dry-rotted. They can maintain a pressure within about 5 PSI of 35 for about a month. However, the cracking has me worried. Also, the spare is a 31X10.50, while the others are 235/75/15s.
    Also, I have locking lug nuts. The key is stripped. Getting a new one is on the to do list.
  2. Ignition
    On cold starts, she runs super rough, kicks a check engine light, and smells incredibly rich. If I throw her into drive while she's throwing her fit, she stalls, and it's a pain to get her to restart. The issue is either in the ignition or fuel system. Plugs and wires say motorcraft, and the dizzy appears fairly old just upon visual inspection. I would say the dizzy may be original equipment, plug wires replaced once or twice, and the plugs are probably fairly old. I'll replace parts one by one until the problem goes away.
  3. Intake/Fuel Delivery
    I know that I'm probably going to have to junk the old injectors. This is where I'm starting on my rough idle issue. However, I'm probably going to do my first major performance upgrade here. I'm going to look for a Lightning intake manifold, performance throttle body, and new injectors. I'm hoping that this helps me restore some of the performance lost by the aging engine.

Minor repairs needed
  1. Windshield
    This thing has more crack than an inner-city house of ill-repute, if you catch my drift. Windshields should be easy to pick up at a junkyard. Also, the current windshield has a leak at the top of the windshield, directly over the steering wheel.
  2. Fog Lights & Electrical
    The fog lights on top of the grill guard work intermittently at best. One below is broken. I'm planning on replacing both, and rewiring the whole system. There is a birds nest of wiring underneath the hood, by the battery. I plan to find out what's actually being used, keep it, and get rid of what's not. Also, the extra 8-10 feet of wiring for the fog lights is quite useless. This is all getting replaced at once.
  3. Brakes
    Rear brake line shot, causes intermittent rear lockup. The brake line isn't a major fix, but I'm going to crack open the drums to see if she's not in need of wheel cylinders, shoes, and drums. It's a major fix on such a small budget.
  4. Computer Control
    I need to figure out what exact setup I have. Under my dash, I've found a couple small units. One appears to be a performance chip. This could be part of why my mileage SUCKS. It may also be affecting my trans, but I'm not sure of this.
  5. Trans
    The trans feels to be in good shape. She shifts fairly quick, the shifts are crisp (perhaps a little stiff), but struggles with the 2-3 upshift. A fluid, filter, and trans kit in a bottle treatment may resolve the issue. I'm not looking for forever, just a couple low mileage years out of her.

But, here are the plans:
It's not an immediate plan, but I want to find a 98-01 F250 donor with V10 (2V), Auto, 4x4.
I'll drop the V10 in the Bronco. I've heard of this done before on an F150 4x4. Unfortunately, the vehicle was destroyed a couple years ago in the Texas wildfires. I'll largely be going it on my own.
I'll work as much as possible with parts from the 5.4, from which the 6.8 was spawned. I'm going to get the camshafts custom ground by Premier Performance in Jordan Valley, Utah. I'll also be getting my fuel system, intake, computer tune, and more while there.
A KB supercharger is in my dreams :-)
V10Supercharger_zps0ce6a5c1.jpg

I'm looking for the 5R110 transmission. Because she'll spend 99% of her life on pavement, she needs something to aid mileage.
I'll take whatever tcase comes from the F250. I'll see if I can adapt the stock switches for the tcase and hubs. I'm thinking of using the existing Tcase as a doubler, but I'm not sure if that's what I want to do.
I'm going to put Sterlings under her. On the rear, I'm going to run the Auburn Gear ECTED. I like the ability to go full time limited slip with optional near-spool operation. On the front, I'll go OX or ARB. I'm thinking 4.88 with 35" tires should be plenty of gear for me. On the rear axle, I'm also going to replace the drum brakes with disc. Safety first!
I'm going to look for a quiet, yet highly aggressive exhaust. I do live in the inner-city, so I do NOT want the cops called every time I start her up. What I plan is to build my own shorty headers, run racing cats in their stock location on a 3.5" collector. From there, I will place a small X-pipe in place of the stock Y. I will place two Flowmaster Hushpower mufflers where the stock units would go. At the end of the exhaust, I want to place two Flowmaster Super-10s before quad tips. This should quiet her down, while giving a hyper-aggressive tone.

The exterior appearance will change radically. Everything, and I mean everything will change. She'll go from black to blue, with a Denver Broncos logo on the hood.
The current grill guard is a joke, as is evidenced by it being bent out of shape. I also really haven't liked the bumpers on these Broncs, they're too plain.
I'm looking at the Iron Bull Enforcer, as seen here. I'm not going the ordinary route of getting their coating (similar to rhino-liner) and will chrome it. Should be attention-grabbing and beautiful.
ironbullenforcer_zpsb019818d.jpg

I'm going to go with the Fiberwerx Raptor Front end conversion. It may look a bit strange, but unique is what I want. I'll stick with the OEM grill, just get it painted to match the blue and orange paint scheme.
BroncoRaptor_zps1c2cff9f.jpg

And the rear
RaptorRear_zps651f096a.jpg

The headlights will be replaced with these.
Raptorheadlights_zpsb9396f89.jpg

And Taillights
Raptortails_zpsd18a6f4d.jpg

I'm going to use 2x2 LED foggers in the pockets. On top of the bumper and under the bottom bar, I'll use an LED light as close to the width of the opening as possible. These will all be relayed onto a single circuit.
In the 3 openings, I am going to use Ruffstuff HIDs. These will all be on a single circuit.
I'm going to get an LED bar to mount about 2" from the top of my windshield, that is full width. It's a bit blurry, but this is pretty close to what I want. I saw this at the Denver Auto Show, on a Ford Raptor.
IMAG0108_zpsd50f4de4.jpg

The rear bumper will again be an Iron Bull unit. I'll have 2x2 LED lights in the pockets, relayed to the reverse lights. I strongly dislike how blind backing up in this truck really is, so I'll put in a hidden reverse camera that goes to a small monitor in the rear view mirror.
Rearbumper_zpscfd3da64.jpg

I do dislike how low the bumper appears, and the gap that is left. However, on the Broncos, this is necessary to accommodate a larger tire on the swing-away. I'm going to be running 35s. There should be plenty of room for the 35" spare. This shows a 31X10.50 spare. Granted, I will need to modify the tire carrier to accept 8-bolt wheels, but you get the idea. There's plenty of space here.
IMAG0077_zps92639425.jpg

She will be sitting on a 6" lift. Of course, with the Sterlings, I'll have solid front and rear axles. I'm going to maintain my coil spring front suspension, and junk out the rear leaf spring setup for 4-link.

What do you guys think?
 
UPDATE: 4-8-13
In scouting out the brake hose replacement that I will do Thursday or Friday, I made a few small discoveries.

  1. Random hose
    Randomtube2_zps323e0c80.jpg

    Randomtube_zps9465f1f0.jpg

    It dead ends right up there on the frame. I don't know what the hell it's doing there. It almost looks like this tube has something to do with the brake fitting where the leak is.
  2. Brake fluid leak
    Holycrapgrease_zps7f5da80d.jpg

    I needed to replace the brake hose anyway because it was making my rear drums lock up and smoke. I'll clean it up a bit and see what's going on. It might be an issue with the old fitting. It's not that bad of a leak, but it's there.
  3. Wasp nest
    Waspnest_zpsd5c9ed0e.jpg

    Oh hell no! I don't wanna deal with these guys! I'm lucky that it was abandoned and that it's still fairly early in the season. We're getting a foot of snow tomorrow, and I'll get rid of this when it dries up. It's also right next to the filler tube, making me even more paranoid.
 
I changed my mind on the bumper. The Iron Bull Enforcer doesn't really mesh with the attitude of a Raptor conversion. I'm looking at a pre-runner style bumper. I'm thinking the one by Unleashed Motorsports would work just fine.
BroncoBumper_zpsd21f80f4.jpg

I've done some more research about the engine and transmission combination that I want.
The camshafts that I want will be a custom ground set. I want to take some of the specs from cams for 5.4s, and apply it to a 6.8 V10. The 6.8 was essentially a 5.4 V8 plus 2 cylinders.
I'm thinking .490/.480 lift, 261/278 degree duration, and lobe timing proper to the 6.8 V10. I want an asymmetrical cam so I can get longer duration at high lift, meaning greater flow. This means power up high on the RPM band.
Of course, the supercharger is still on the wish list, especially a Kenne Bell. If I can run higher boost, then I can get some very impressive power. Perhaps 700-800 HP.
V10_zpsbc75845d.jpg

I also changed my mind on the transmission. I'm not 100% on fitment, but the 6R140 is used behind the 6.2 V8 that replaced the 6.8 V10. I'm choosing this transmission because of power-handling as well as the fuel efficiency bump it will give. In addition, a Tcase from the Powerstroke should be capable of handling everything this V10 can dish out.
6R140_zps8dc93559.jpg

I'm thinking the front axle will be built Yukon Gear D60. The rear will be a built Yukon Gear Dana 80 SRW. It will be an 8-lug conversion. The gears will be 4.10. Both the Front and Rear will be ARB Air-Lockers.
I've selected the tires. Dick Cepek Mud Country in 35X12.50XR15
DCTires_zps492ca687.jpg

I'll need help with the 4 link rear suspension. When I get it figured out, it should be awesome.
 
How's the rig comin?
 
No updates, got fired from my job delivering pizza, so money is wicked tight until I get financial aid.
Then, I'll get the tires, brakes, ball joints and O2 sensor done. I gotta keep it down to about $500. If I'm able to get a job that fits my hours of availability, I'll be able to dump every single penny into accumulating parts for the aesthetic transformation.
 
That unidentified hose you were wondering about is the vent for the rear end. the brake lines use the same mount.

Richard
 
Thank you for that info, Richard. It's good to know. Is there any harm if that tube gets plugged up?
 
It could cause oil leaks, as the oil heats up it expands and the air needs some place to go. That's why the vent tube. If the vent is plugged the air pressure could force oil past the seals.

Richard
 
Good to know. It appears like it may be clogged, but I see no evidence of leaks. I'll check it out sometime.
 

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