ECORS Class A race rig build

[broncosbybart]

Been working like mad on it, though you wouldn't know it by the progress being made...

Here is the front axle housing, bare and ready to be assembled. I put new axle seals in it. The carrier is a True Trac. The rules only allow for 1 locker, and the rear is getting a spool, so this is going in the front.



Pattern came out good. Gears are 4.10's.

[broncosbybart]

Next, new Wild Horses spindle bushings were pressed in.



Assembled the knuckes, new ball joints, and greased the axle shaft joints.



Next, Clay fabbed up some DOM to use for a new rear crossmember. I welded it in place then he cut out the original crossmember, as it was going to be in the way of the rear axle (it is going to be moved 4" toward the rear).

[broncosbybart]

I got a 4x4 F150 box in a swap for the EB ps box. Major setback as the sector shaft was no good.



I got a 4x2 box out of the junk yard to convert it, but the sector shaft for the 4x4 box stays with it. So, I had to find another ps box. Fortunately one turned up locally. So, now I have 2 housings but only 1 good box. I bought a rebuild kit and pressure hose. The box had a ton of mud or stop leak or some crap in it. Other than that, it turned out great!

[broncosbybart]

Now we hop around a bit. I fit and welded a truss to the rear housing, as well as a WH skid plate.



Clay cut out some gussets for the upper coil buckets and then I welded them into place.



Next, I installed the front axle.

[broncosbybart]

Next came the fitting of the ps box to the frame. The kit I got took some major fabrication. I ended up cutting 1" holes in the outside frame rail to insert the new tube to support the mounting bolts. Here are a few pics.









Then came the welding of the reinforcement plate.

[broncosbybart]

Finally, the box can be mocked up. The engine cross member is right in the way of the rear upper bolt.. Have to fix that tomorrow.



Next, Clay's buddy cleaned and painted the axle housing. I don't have a pic of it before paint, all welded up. We installed the 3rd next. I don't have any pics of that, either. I went with a 9+ nodular housing and full spool. It took a while to set up, and didn't come out as good as I would have liked.

Here it is painted, assembled, with new grade 8 fasteners. Doing a freaking frame off resto to a race truck that is gonna get beat to death!!!


Got a big, huge pinion guard on the front as well!!!

[broncosbybart]

Last thing we did was mock up the rear. I tack welded the spring hangers in place. The rear shackles came from Nick at Nick's Trix. Very nice!!! I flipped the rear hanger so that I can later weld a big honking tube to them for reinforcement.





The u bolts and plates came from WH. Super stout!!!

[SC74]

Looks like you are moving along FAST! What body are you putting on it? Good Work - keep it up!

[broncosbybart]

Thanks! Been trying like mad to shoot for the season opener on March 12!! Got a ton of work to do...

The tub is on page 1, but looks like this...



It will get a new cage and a lot of work done to it, but probably not before the first race.

[NicksTrix]

looking good there. you're moving in the right direction! hammer on...