PELLEY's 1990

EL MARTILLO · Post by **EL MARTILLO** » Sun Apr 17, 2011 4:19 am

hey how did you like the mojave road ? been a few for me but I had a blast.
I took my jeep last time, looking forward to doing it in the bronco

tcm glx · Post by **tcm glx** » Sun Apr 17, 2011 8:09 am

Build looks great!!

Chris from this forum is selling his entire front clip:
http://www.fullsizebronco.com/forum/sho ... p?t=192412

PELLEY · Post by **PELLEY** » Sun Apr 17, 2011 8:34 am

CBDuner: Thanks! I had been meaning to post an update, but have been on the busy side. Thanks for staying tuned though!

EL MARTILLO: That was the 2nd time I had done it. First time we did Laughlin to Barstow, then we did it backwards this last time. The Bronco did great! Only place I used 4x4 was the lake bed. It was real mushy this trip, it had just rained a few days prior. The only issue with the Bronco out there is it's width. The long 15 mile section in the Joshua trees was I little tight. I got through no problem, but I gained a few scratchs. I was hauling ass though... I am sure some could have been avoided. I have a great GoPro video of it, just waiting for a friend to send it to me... Nice jeep by the way!!!!

TCM GLX: Ya I saw that clip on there. If he still has it in a week I might go get it. Just a long drive for me... My $40 top ended up costing me $100 after gas, so I am trying to work something out. Thanks for the heads up though!!!!

PELLEY · Post by **PELLEY** » Sun Jul 17, 2011 4:01 pm

OK so an update is long over due... But I have been busy with other things. Also almost sold the Bronco... Both my wife's 4Runner and my Bronco died on me a month back, and I was getting tired of the un-reliable Bronco. Well justice prevailed and I decided to keep it. I am no rich guy and can't buy a newer ride cash, plus I didn't want a freaking car... and I don't need another payment... So ya, keeping the Bronco, and decided that if I put $1500-$2000 into it, I can clean it up nice, and make it a little more reliable, and just keep on driving. I only drive it 5 miles a day, so it works as a daily driver for me.

So here is what has gone on since I last posted. Got the front bumper 95% done (are these things ever done). Got the skid plate mounted, and even managed to put a nice little vent screen in it to help with air flow. I do need to move one of the skid plate tabs. In my mad dash to get it done, one of the tabs was not put in the right spot, you can see where it is missing in the skid plate if you look close. Also need to get some lights a mount them up. I am at a cross between the Kragen/HID-X lights, or getting some Hella 700ff's and converting them to HID's. Not sure which setup works better, they probably work out close to the same price all said and done...

Also started building my rear bumper today with some material I had laying around from side jobs. Very simple two tube design. Trying to keep it similar in style to the front, while making it look right. So far I have done the major tube work. Next is placing the hitch mount and support tubes. Then I am going to move the license plate back onto the rear bumper, and plate in the rest of the area between the frame rails. I think it will be bitchin with the plate on one side, then one or two of the trailer style reverse lights on the other (the oval LED ones that people use in light boxes). I have to give credit where it is due, I saw Keifer's rear bumper and liked how he did that with the plate, and the 2 small lights. I am using that idea, but doing it my way I guess you could say. I tried to keep the bumper as high and close as possible. I didn't want anything hanging out too much, I know I smashed my stock one up bad on both sides, pushing it into my fenders and tail gate, so I want to avoid that!! Also plan on doing the rear fender trim like some do to bring the bottom edge up to the bumper for more clearance and of course, the look, haha.

As far as future plans go, I am still working them out. I am still keeping the early 90's body style, no update for me. I still need to find at least a drivers side front fender, and a new hood. I wish I had the cash to swing for a drop center, but I think I am just gunna stick with a stock steel hood for now. Once I get those two pieces, I will remove the render flairs, get everything mounted up, do a little prep work, and take it down to the local paint shop. I am debating on keeping it white, or maybe going a light or dark grey... any thoughts???? After paint I plan on getting a brand new grill and lights from ebay, they are rather cheap and clean things up well. Might go for the clear corners like Keifer put on his wife's ride... we will see. Also gunna get some new carpet, and headliners for the inside to clean things up.

Also need to give the suspension some more love. I sold the FOA's I had when I thought I was gunna sell this thing. So I need to get some good shocks for the front of this thing again. Haven't decided if I am going to go 14" shocks in front of the beam, or move my bump stops and mount some 10" shocks behind. I know the 10" shocks are much easier to mount, that just means I will need to get creative in moving my bumps, probably in front of the beam, and make the 4" travel again... Also need shocks and springs for the rear... all in good time. Ok ramble fest complete, here are some new picture, I even busted out the DSLR instead of using the handy iPhone this time, haha.

BDKW1 · Post by **BDKW1** » Sun Jul 17, 2011 11:39 pm

Why shorten the bumps?

If you open up the hole in the spring bucket slightly you can slide the can down inside the spring. Make a landing pad for the bump that screws on to the radius arm bolt. Easy money.

PELLEY · Post by **PELLEY** » Mon Jul 18, 2011 7:15 am

That's a good idea, but would it really work? I am no expert here... I have seen it done on jeeps, but how would it translate to TTB with the constantly changing spring arch? I could see some potential contact at bump when the spring starts to arch in... Maybe I am wrong, again I am no expert... Do you have any photos of this setup???

BDKW1 · Post by **BDKW1** » Mon Jul 18, 2011 10:00 am

Worked well for Me. I did have the buckets reinforced a little. Cut the stock front mount off and plated it in all the way down. Then had a tube from the frame up to the top for longer shocks to mount to. Springs never rubbed on the bump. They did rub a little on the new front gusset though. I just gave the old landing pads to a buddy of mine for his Bronco. When he gets around to it I'll get some pics as I never took any of the Barge.

BTW, bumps in the front was one of the best things I ever did to that truck.

PELLEY · Post by **PELLEY** » Mon Jul 18, 2011 1:03 pm

Pics would be great!! And great info. When I get around to mounting bigger shocks up front I will finish re-enforcing the front side of the bucket I will give that a shot. I do have to say, since I only have the 5100's, the added cush of the bumps has been amazingly helpful!!! I am very glad I got them, and am actually excited now about being able to use the full stroke of the bump, 2" is nice, but I have bottomed them out a few times... Haha

PELLEY · Post by **PELLEY** » Mon Jul 18, 2011 5:15 pm

Scored some good deals at the local pick-a-part today. Got a new hood, drivers fender, glovebox door, and tailgate with glass and all for $150!! Just need to get these parts on and do a little prep to get this beater ready for paint.

PELLEY · Post by **PELLEY** » Fri Jul 22, 2011 10:42 am

Good day for the Bronco! Picked up a set of 14" X 2.65 Bilstien shocks for the front off DR. $350 shipped to my house, good deal I'm thinking.

Guy says they are like new, but I want to get these as close to dialed as I can before install. I know a few guys on here are shock guru's... Who here can help me get set up with the right valving, I'll bring or ship them and pay to get them done right...

Also on a small note, but big to me, got my glovebox in yesterday. I know, small shit but I have been without for 5 months now, and had to make a new latch on the dash as the stock one broke off.... Haha

tcm glx · Post by **tcm glx** » Fri Jul 22, 2011 11:11 am

PELLEY wrote:Good day for the Bronco! Picked up a set of 14" X 2.65 Bilstien shocks for the front off DR. $350 shipped to my house, good deal I'm thinking.

Guy says they are like new, but I want to get these as close to dialed as I can before install. I know a few guys on here are shock guru's... Who here can help me get set up with the right valving, I'll bring or ship them and pay to get them done right...

Also on a small note, but big to me, got my glovebox in yesterday. I know, small shit but I have been without for 5 months now, and had to make a new latch on the dash as the stock one broke off.... Haha

Thats a good deal right there. I would suggest going straight to Joel at Bilstein. He has done set ups for many of us on GFB, as a matter of fact, he has a "pre set Bronco package" he does for the front. Would be a good idea for him to go through them while he checks the valving, and call it done.

You can call him at 858-335-3300 , or send him a PM, he is on these board, "Random Thoughts Racing"

PELLEY · Post by **PELLEY** » Tue Jul 26, 2011 5:15 pm

Well today was a good and bad day... Got my shocks today, but they are not the 14" shocks as advertised, they are 12" shocks... And as far as condition goes, fell a little short as well, but that is expected when buying used over the internet right!!! Maybe I should have been patient and waited until one of the swapmeets, but then my wife keeps me busy so who knows if I would have even made it, haha.

So the dilemma at hand here is do I try and send these back to the guy, or do I make lemonade and put these in the rear???? Please help me with inputs here!!!! I personally wanted to mount some longer shocks through the bed and tie into a future cage as it would make valving much easier, and the shocks wouldn't have to work so hard. Or I was gunna put some bypasses under the bed as most do. So the question is will these do the job. I don't plan on hitting whoop section after section all day, but I do want to know my suspension is there when I need it...

Along with the length issue the shafts also have some gouges and they do look like they need a rebuild (the rebuild I was expecting). They are in, well used shape I guess. Depending on the feedback I might try and get my money back, but I still feel these were a good deal if they don't require new shafts and all. Trying to figure out a plan here, please help!!!

Few pictures:

Hard to tell in the picture, but the small gouges are there. It looks like someone cleaned them up, and actually did a decent job. You can see in the lines of the light where they were cleaned up, again, probably hard to see in the picture...

tcm glx · Post by **tcm glx** » Tue Jul 26, 2011 6:01 pm

Rebuild, and slap in the rear. They are perfect for that exact use!

bajascott · Post by **bajascott** » Tue Jul 26, 2011 8:26 pm

you still got a pretty good deal,350 is not a bad price, you can use these on the front too if you want, i run 12" kuster on the front of mine it works great.

PELLEY · Post by **PELLEY** » Wed Jul 27, 2011 12:58 pm

I am thinking that I will be putting them in the back, like Tony mentioned. Should work good for what I can do. Got in touch with Joel to get them dialed in and repaired, waiting to see what he thinks the damage will be...

Scott, what kind of wheel travel do you get with your 12" shocks in front of the bucket? I know when I was cycling the front end around I can get a clean 14" right at full extension of my coils. With the shock a good 5" in from the wheel I was thinking a 14" shock mounted on the outside should get me the 14", then strap it at 13". Does your 12" allow it? I was also considering mounting behind the bucket, won't use all of the shock, but with a smooth body it should be non issue. I just don't like mounting there, makes me think the shock will have to work a little harder than in front. Correct me if I am wrong, I am no expert, or maybe the difference is slight and not worth noting... I think with just throwing them in the back, I can in turn get what I want for the front. Thinking 14" in front of the coil, then if I want to go coilover down the road, I already have my 2nd shock in place! Would make for a well controlled front end.

bajascott · Post by **bajascott** » Wed Jul 27, 2011 1:09 pm

mine is mounted in front,and i get 15" and it uses 90%of the shock. mine are 3"bypass' with 3"piggyback resivoirs so i had to get creative with the mounts but it works good and if i were to use a softer longet spring on the front and modified my u-joints and ported the passenger beam out i could get more.but why? its not how many inches you have its how you use those inches.(yes there is a pun intended haha)
i think that the reason most use a 14" on the front like that is due to them getting worked and hot so the more oil the cooler it runs. but for what the most us do with our broncos in real life a 12 is plenty.we are not racing

PELLEY · Post by **PELLEY** » Tue Aug 02, 2011 8:14 am

Scott, thanks for the great info. After talking to a few others, and thinking about how I want to proceed, I am going to put these shocks on the rear. I think when I go to the front I am just gunna bite the bullet and go C/O...

As far as updates go, this thing has been kicking my ass!!! I dropped the tank to change my sending unit (gas gauge was not working). Got the sending unit in no problem, then as I was putting the tank back up, it fell off the jack and broke both of my fuel line fittings... It was a dumb mistake on my end, should have emptied the tank completely, but I was in a rush...

So long story short, nobody makes replacement lines, and they are all sorts of complicated with trying to find the right fittings and parts. Scott was a badass and mailed me a bunch of random fittings and I was able to frakenstein some lines together.

I do have the proper parts on order to make new lines. They are still a couple weeks out though. So that said I couldn't wait any longer to get this thing running again, since it is my DD, so I went ahead and did the access pannal as others do. This too is slightly a temp job as I do not have a bigger floor section to replace my cutout. Sooo I made some tabs, and it is back in there for now. Once I find a new section of floor it will be as easy as drilling a few holes, all the hard work is done.

I have also been doing some work on the back bumper while it was down. Now that the tank is back in, I can finish my hitch tie ins, and wrap that thing up as well!

Few pictures:

Maximised the life of the cutoff wheel!!!! Haha

Rear bumper

Fuel gauge works!!!! I need gas...

ChaseTruck754 · Post by **ChaseTruck754** » Tue Aug 02, 2011 10:40 am

PELLEY wrote:Maximised the life of the cutoff wheel!!!! Haha

You'll thank yourself over and over again later for doing the access panel back there now.

And as far as that cutoff wheel - I run mine until the hit the washers on the arbor. They come off about the size of a silver dollar. Makes them interesting to get off at times!

PELLEY · Post by **PELLEY** » Tue Aug 02, 2011 11:13 am

And as far as that cutoff wheel - I run mine until the hit the washers on the arbor. They come off about the size of a silver dollar. Makes them interesting to get off at times!

Haha right. I usually just tighten by hand with the wheel as leverage. Does make for interesting removals for sure when you take them down to nothing...

PELLEY · Post by **PELLEY** » Sun Aug 07, 2011 5:05 pm

Wrapped up the rear bumper, well for the most part. Waiting for LED license plate bolts, and my KC oval backup light. KC also makes an amber light too, might put one of those on the bumper too, waiting to get the first light and see how much room I got... Oh ya, and I need to cut out some holes in the 3/16 the receiver is in for chain hooks... noticed that today after I was just about done.

Pics of bumper:

Next on the list is rear shock mounts, and getting my new (to me) shackles installed. The shackles are 7" hole to hole. Not enough room under the bed for them. Trying to decide whether to cut the floor, or to drop the shackle hangers. I saw Solo's little hanger drop kit. I think I might have to fab me up my own version. Do the drop and make a re-enforced cross member back there while I am at it.

Also having 2nd thoughts on getting this thing painted. I have some money set aside, but I am thinking I want to do some more value added stuff. Thinking of getting some new Deavers and maybe another set of 2.65 Bilsteins so I can get all four corners under control. Thoughts??!!

PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990

Re: PELLEY's 1990