Parts and upgrades
It's funny: when I have time I don't have much $, and when I have $ I don't have much time.
Haven't made much progress in the way of actual fabrication on the Bronco lately, but I did order some goodies.
RuffStuff Dana 60 and Sterling 10.25 diff covers:
RuffStuff 6" RSK for the Sterling:
RuffStuff Sterling rear disc brake kit:
I am very impressed with the quality of all of the RuffStuff items. The diff covers are 3/8" thick, the D60 cover weighs about 25 lbs. and the Sterling cover weighs about 40 lbs. The RSK brackets are 3/8" thick as well; they are well-built and super stout. The rear disc brake kit brackets are 3/8" thick (notice a trend here?) and look like they will install fairly simply. All of the hardware included is grade 8.
Borgeson steering shaft:
Yukon kingpin rebuild kits and Warn 35-spline hubs:
I don't think these new Warn hubs are going to work with the Dana 50 spindles that I got from a '97 F250 (the way the hubs engage the spindles on the '97 Dana 50 are significantly different). Which means I may have to adapt the dually hubs from the Dana 60 I already have or get a new set of spindles.
Also, I had planned on using Reid Racing bronze upper kingpin bushings. However, ECGS states, "designed to replace the OEM nylon cone bushings in severe-duty applications where the OEM bushings succumb to accelerated wear and premature breakage. Bushings are designed specifically for rockcrawling, rockracing, and other extreme off-road motorsports. Designed to be used with aftermarket adjustable-preload highsteer arms or shimmed "spring eliminator kits" instead of the OEM spring and cap retainer." High-steer arms are nice, but that's extra $ unnecessary for this build. I looked around fairly thoroughly for a kingpin spring eliminator kit and I couldn't find any mention of them anywhere.
Redhead steering gear:
USA Standard gear 35-spline stub shafts. I was going to use chromoly shafts, but decided against it when I saw the price difference. Realistically, this BKO will be on the road 90% (or more) of the time. If I break these, I'll upgrade:
ECGS kingpin removal tool:
This is a nice tool, but unless you're planning on rebuilding kingpin Dana 60s for a living, I'd pass. I misunderstood the listing on the ECGS website and thought I was ordering both this and the allen wrench. The cost was almost $40 shipped.
I also upgraded my MIG setup. I was using .035 Innershield flux core wire, but got tired of all the splatter. So I picked up a 150 cu/ft cylinder of Ar/CO2 75/25 mix, along with both .030 and .035 solid wire. I've been running the .035 and practicing on some 1/4" scrap steel I have laying around. It welds so much cleaner than the flux core. Since I now have a bottle to go along with the welder, I bought a cart to keep it all together and have it mobile. Much nicer to move around.
I also found the steel table you see in the picture below (to the right of the MIG cart) on craigslist. It has a 3/8" top, much thicker than the sheet metal work bench I was using before. I just need to get a oxy/acetylene torch, and the majority of my steel-working tools will be complete.
I still need to put an order in with Artec for the D60 and Sterling trusses and front 3-link kit, but I've made some decent progress on parts acquisition... now I just need to find the time to get this put together.
It's funny: when I have time I don't have much $, and when I have $ I don't have much time.
Haven't made much progress in the way of actual fabrication on the Bronco lately, but I did order some goodies.
RuffStuff Dana 60 and Sterling 10.25 diff covers:
You must be registered for see images attach
RuffStuff 6" RSK for the Sterling:
You must be registered for see images attach
RuffStuff Sterling rear disc brake kit:
You must be registered for see images attach
I am very impressed with the quality of all of the RuffStuff items. The diff covers are 3/8" thick, the D60 cover weighs about 25 lbs. and the Sterling cover weighs about 40 lbs. The RSK brackets are 3/8" thick as well; they are well-built and super stout. The rear disc brake kit brackets are 3/8" thick (notice a trend here?) and look like they will install fairly simply. All of the hardware included is grade 8.
Borgeson steering shaft:
You must be registered for see images attach
Yukon kingpin rebuild kits and Warn 35-spline hubs:
You must be registered for see images attach
I don't think these new Warn hubs are going to work with the Dana 50 spindles that I got from a '97 F250 (the way the hubs engage the spindles on the '97 Dana 50 are significantly different). Which means I may have to adapt the dually hubs from the Dana 60 I already have or get a new set of spindles.
Also, I had planned on using Reid Racing bronze upper kingpin bushings. However, ECGS states, "designed to replace the OEM nylon cone bushings in severe-duty applications where the OEM bushings succumb to accelerated wear and premature breakage. Bushings are designed specifically for rockcrawling, rockracing, and other extreme off-road motorsports. Designed to be used with aftermarket adjustable-preload highsteer arms or shimmed "spring eliminator kits" instead of the OEM spring and cap retainer." High-steer arms are nice, but that's extra $ unnecessary for this build. I looked around fairly thoroughly for a kingpin spring eliminator kit and I couldn't find any mention of them anywhere.
Redhead steering gear:
You must be registered for see images attach
USA Standard gear 35-spline stub shafts. I was going to use chromoly shafts, but decided against it when I saw the price difference. Realistically, this BKO will be on the road 90% (or more) of the time. If I break these, I'll upgrade:
You must be registered for see images attach
ECGS kingpin removal tool:
You must be registered for see images attach
This is a nice tool, but unless you're planning on rebuilding kingpin Dana 60s for a living, I'd pass. I misunderstood the listing on the ECGS website and thought I was ordering both this and the allen wrench. The cost was almost $40 shipped.
I also upgraded my MIG setup. I was using .035 Innershield flux core wire, but got tired of all the splatter. So I picked up a 150 cu/ft cylinder of Ar/CO2 75/25 mix, along with both .030 and .035 solid wire. I've been running the .035 and practicing on some 1/4" scrap steel I have laying around. It welds so much cleaner than the flux core. Since I now have a bottle to go along with the welder, I bought a cart to keep it all together and have it mobile. Much nicer to move around.
I also found the steel table you see in the picture below (to the right of the MIG cart) on craigslist. It has a 3/8" top, much thicker than the sheet metal work bench I was using before. I just need to get a oxy/acetylene torch, and the majority of my steel-working tools will be complete.
You must be registered for see images attach
I still need to put an order in with Artec for the D60 and Sterling trusses and front 3-link kit, but I've made some decent progress on parts acquisition... now I just need to find the time to get this put together.
Last edited: