CopyKat's 4X4 BroncoIV build.

[CopyKat]

Here the BOV is mounted. Just need to do the low pressure side now.

http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/engine%20trans%20swap/Engine%20rebuild/Turbobuild062.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/engine%20trans%20swap/Engine%20rebuild/Turbobuild063.jpg

[CopyKat]

Lots to update.

Here is the BOV finished.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/engine%20trans%20swap/Engine%20rebuild/Turbobuild064.jpg

Pulled the truck out to turn it around to get the rear bumper worked on.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Turbobuild067.jpg

While it was out I took it for a small spin.
YouTube - Turbo 4.0L shakedown

Got the truck back in the shop and started to clean things up.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper007.jpg

Got the bumper made and installed.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper006.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper009.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper008.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper010.jpg

Changed out the muffler. Installed a glass pack bottle.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/engine%20trans%20swap/Engine%20rebuild/Turbobuild.jpg

With the bumper done it was time to work on the tire carrer.
Upper latch I had to make. Didn't have the factory one any more.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper015.jpg

Lower latch.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper016.jpg

Mechanism for the lower latch.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper017.jpg

Done.
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/Rearbumper013.jpg

Now I just need to build the harness to control the 7th and 8th injectors and I can start tuning the truck and up the boost to 6 PSI.

[Ckrue689]

try running that bov open instead of back into the intake, it should really turn some heads to hear that thing pop off...

[CopyKat]

Quick update.

Blew the seals in the turbo and it started burning coolant into the #4 cyl. :(

Since I was having ovwerheat issues I think I warped the drivers side head. There were no signs of blown headgasket. Puilled the turbo off to find a kinked return line and the turbo and my exhaust was coated in coolant-oil mix (Caramel)

So I have pulled the turbo off and put the 95TM fast burn heads and headers back on. I'll save the turbo for another project.

[Blanco]

Bummer dude & after all that hard work. :(

[CopyKat]

Bummer dude & after all that hard work. :(

Not to worry Cam. All that hard work has not gone to waste. Think of it as R&D.

[Blanco]

Not to worry Cam. All that hard work has not gone to waste. Think of it as R&D.

Good attitude. :)

[CopyKat]

Here are some updates.

Now running 35's:D

Here are a couple updated pictures.

Sanding the doors and still have some more work to do on the fenders before I can shoot the epoxy primer and paint.

http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Fenders/brotruck001.jpg

http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Fenders/brotruck003.jpg

http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Fenders/brotruck004.jpg

[CopyKat]

Now for a splash of color. This is just going to be the winter paintjob. It's a 50 foot paintjob. So it's far from quality. I was thinking about putting my Class3 decals on the bottoms of the doors but to no avail not much is left of them. So I doubt they will stick over holes.

http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/colorcoated001.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/colorcoated002.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/colorcoated006.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/colorcoated005.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/colorcoated007.jpg

[Blanco]

Thats really starting to look great!

[CopyKat]

I thought about going all white but there are just too many White Broncos on this site.;)

I think I'm still going to put the Class3racing decals on, just not on the doors like I originally planned. Going to ditch the Rancho decal and put them there on the back windows.

[CopyKat]

Here you go Cam

http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/Exterior%20mods/colorcoated.jpg

[Blanco]

Gotta love the way that looks with the white top. http://www.thewebwheeler.com/forums/images/smilies/7.gif

[CopyKat]

Gotta love the way that looks with the white top. http://www.thewebwheeler.com/forums/images/smilies/7.gif

It really pops out with the blue background.

[Yikes]

Sweet! Nice to see it painted. It has a European rally look to it.

[CopyKat]

Sweet! Nice to see it painted. It has a European rally look to it.

The splash guards do that don't they.

[CopyKat]

Needs a few updates.

Designed these and tacked them together. They are D44 TTb conversion brackets. Yup I'm planning to do a D44 TTB. Just need to mock them up under a truck so that I can make any changes needed before I weld them up solid.


http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/front%20susp/D44%20TTB%20Swap/d44ttbbrackets003.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/front%20susp/D44%20TTB%20Swap/d44ttbbrackets004.jpg
http://i128.photobucket.com/albums/p198/Villanmotorsports/BIV%20Bronco/front%20susp/D44%20TTB%20Swap/d44ttbbrackets001.jpg

[Blanco]

Have you wore out your current set up already?

[CopyKat]

Have you wore out your current set up already?


Time for an upgrade! Going to run a cut and turned D44. The specs on the brackets are 1.5" lift, with both the D35/D28 and D44 pivots. This makes the D44 nearly a bolt on. Yes it's going to be a full width setup. Just easier to find parts if I break them.

[Blanco]

So I assume you gonna swap to a full width rear axle as well?
& if so will it all still fit within your flares?

[CopyKat]

The front will stick out a bit. I will be 2.5" wider per side than it is now.

For the rear I'll be using the Explorer 8.8 I had before, and with the spacer/lug adapters i'll be about 3" narrower out back. I can live with that. The rear flares will work with the ex 8.8 and spacers but the front I may be stuck having to make new ones. or extend mine somehow. Just to cover the width and keep the po-po's off my back. Buddy of mine got pulled over last weekend and got a warning for the front tires sticking out his wheel wells. So they are cracking down here big time. I want to keep it as legal as I can. I've got about another 1" per sideI can go, for front axle width, before it's questionable.

[CopyKat]

Some updates as I am collecting some parts.

Got a set of 24 lb/H injectors and plan to put the turbo back on. Hate to see it collecting dust in my shop.

Have a roll of fiberglass to make a fiberglass hood skin. This time I am going a different route and will make a quick mold off the current hood and will modify from there. Then make a part out of the mold. Have enough glass to make a mold and a part.

Picked up a set of Fox 2.0 x 14 resevoir shocks for the front. When the D44 goes in I'll have to make a new coil bucket and will make a new shock hoop with over engine tie bar. Also have a pair of Fox 2.0 x 10 for the rear. Will be making a cargo area cage to support the shocks similar to how James had his in his B2.