Rod's 84 BabyBajaF100

[AussieRod]

I plan to add a few gussets at the joints, to add some strength. The bumper will go over the hitch point and incorporate the reverse light, trailer plug(s) and a hitch insert will be made up to hold a shackle for tow straping. Tomorrow I will attack the head gasket on my Dad's replacement car and fix a couple of leaking oil seals, new lower ball joints and new rack boots. Then I will replace the valve cover gasket on the truck and the leaking oil light switch.

Randy, I dont need any encouragement to come over permanently, just waiting for the excuse

[flyinbronco]

Damn - I guess I will quit bitching about our smog nazis - at least we don't have to deal with that BS - yet...

"Yet" is the key word here guys.

[ChaseTruck754]

that was my point Rick. We all need to do what we can to avoid that!

[AussieRod]

Damn - I guess I will quit bitching about our smog nazis - at least we don't have to deal with that BS - yet...

"Yet" is the key word here guys.

Don't worry, I'm sure Nazi-fornia is dreaming up something to limit the fun we (you guys too) can have with our trucks and Broncos by limiting the mods we can / are allowed to do.

As an update, I just bought a complete 4WD TTB kit from Ebay here. It has new discs, pads, bearings and seals, it has the radius arms, chassis mounts for beams and r/arms, etc. With the V8 Bronco springs I have here, and adjustable alignment cams, it will go in as soon as I get a few minor jobs out of the way. Selling off my unwanted HEEP parts is progressing slowly, soon I hope to order more for the F100.

[Balls]

Someone needs to build a dual steering box, crossover steering for the TTB!

One could build an idler arm to replicate the steering box on the pass side, then reverse the linkage. That would do it.

Finally caught up with my local authorised vehicle engineer today and gained some info on approved modifications. Some of it isnt good, but most I can get around by being creative. Here is some of the rules pertaining to what I plan to do with the F100:

Maximum legal lift: 3" (75mm) from factory ride height.
Max legal tyre dia: 33".
Max legal track increase: 2" (50mm).
Max legal wheel width increase (from widest factory wheel): 1" (25mm).
Max legal wheel dia increase: 1" (25mm) over largest factory wheel diameter.
No solid suspension bushes (heim joints, monoballs, etc).
DEFINATELY NO heim joints in steering or suspension, regardless that they are usually stronger than a normal tierod end.
Welded steering components must be full pen welded and have a Xray or other NDT certificate to prove integrity.
Any suspension components modified by welding, etc. must be engineer approved and a sample submitted for destructive testing to prove suitability.
Roll over protection for road use vehicles is strictly regulated and MUST conform to the registration body's requirements, which varies state by state.
Coil-overs with heim ends are a NO-NO! (Same goes for shocks)
Yadda yadda yadda, it goes on and on. I wish I was living in the US, as I wouldnt need to worry so much about all this shit. The cops are getting smarter too, now they have a data base to work with to verify any measurements at a roadside check. Its SO hard here to do even half the things you guys can do
BUT, I will endevour to persevere.
EDIT.
We have roadworthy inspections, required when buying or selling..... I need to comply to transfer the truck over to me, THEN I can go to town. Keep in mind, this rules are the LEGAL parameters, it doesnt mean I have to follow them, just need to deal with the cops when I have a road side check and they look too closely

The one saving grace for us Rod, is that we drive someting different and that makes it a little harder for the cops to ping us on things. I drive an BA xr8 ute for work and believe me thay know exactly what can and cannot be done to those things. I've only been pulled over once in the Bronco (20 over while on my way home from a 24hr mountain bike race so was delerious). I got a lot of questions and was able to BS my way out of all of em, I'm sure you would be able to do the same .

[AussieRod]

Yeah, I hear ya. As long as I drive sensibly on the road, I shouldnt attract too much attention. I am going to try and keep as legal "looking" as possible, so they really have to look hard AND get dirty to find anything to defect me for. As a motor Mech, I can find ways to hide the obvious and then I can shoot them down a bit when they start trying to be clever. My 4WD front end should arrive next week, so I can start planning that out, then find the rest of the drivetrain to go with it.

[AussieRod]

Started on my front bumper today. After going as far as I could on the cars I am fixing, I started fabbing.
After removing the stock bumper, I bolted on the mounting plates:

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Flame cut these at work to my own templates:

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positioned the main tube and set the level:

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tacked on the light tabs:

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note the sophisticated alignment tools

[AussieRod]

More progress pics:

[AussieRod]

So far, I have about an hour into putting the bumper together. I cut out and made up all the brackets, tabs and bent the tube during lunchtime breaks and after work, when I had time. A few more gussets and braces will strengthen it up. The underneath braces and skidplate will come later.

[Silverslk]

Looks good Rod!!! Keeping it close in to the body I see. Whats the plan for the skid?

[AussieRod]

Looks good Rod!!! Keeping it close in to the body I see. Whats the plan for the skid?

Andy, I'm planning to run a crossbar at the sway bar mount area, then angle 2 bars back from the main tube to the centre of the main crossmember. Thinking to use some 5 mm aluminum plate or maybe even a 4 mm stainless steel plate (it can be thinner and stronger). I have fog lamps to mount, along with more gusseting and braces. It should do the job.

[hobbyturnedobsession]

Lookin good Rod! I like the bolt brackets.

[AussieRod]

Lookin good Rod! I like the bolt brackets.

Thanks, Randy. I made cardboard templates and did a lot of checking and re-checking before I cut out the plates. They seem to have come out ok so far.

EDIT: After huge days yesterday and today (Sunday), I am beat. After dinner I will go out and put a little more weld on the tube(s), so they dont fall off tomorrow going to work. Maybe I will just remove the bar and bolt the factory bumper on for tomorrow. I dont want anyone at work seeing it until its done.

[philofab]

Thats a rad welding cart you got there...

[AussieRod]

Yeah, a bit unconventional, but with the unpredictable weather we have had lately, I can get it and my tools undercover in a few seconds. And, when I am finished, I pack everything neatly in the barrow and wheel it into the garage.

[BajaBronco13]

Good stuff there Rod. You are making the APEMFB movement proud, lol.

Chris

[AussieRod]

Good stuff there Rod. You are making the APEMFB movement proud, lol.

Chris

Doing my best

[AussieRod]

MMMMMMMMMM, some TTB parts has come into my life.

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My new 4WD front end has finally arrived. I plan to dis-assemble it all. check everything over and figure out what else I need for the complete conversion. The truck is coming off the road for a week or two for some serious work, so I might fit it all then.

[AussieRod]

Whew, it was hot today! So, after a beer, I decided to make some more progress on my bumper.
A few gussets:

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Welded up all the tabs, etc:

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Trimmed, angle cut and capped the main tube ends:

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[AussieRod]

Starting to look like a bumper now. It might not like as good as some of the nice bumpers that adorn you guys trucks, but its functional and has to stand up to the odd kangaroo strike:

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Side on view:

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I was somewhat surprised that my welding was pretty neat. Usually, its not as neat. Must have been that new Aussie Anti-Spatter I was using. Trouble was, it took 4 cans of the stuff!

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