Aonarch’s 2023 Bronco Build

[KRAKEN]

Bronco is looking good. Well thought out build. I'm impressed with your payload data.

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[Aonarch]

Barnes 4WD Spare Tire Reinforcement installed. While my spare tire is lighter than factory, I do have the two rotopax hanging off of it, and the JCR table, plus an axle, and three bags attached to the molle. That adds up to a lot of weight.

Notes: You really need to shove cardboard firmly into the body gaps to keep it from sagging. I didn't do a good enough job and had to use a pry bar wrapped in foam when reinstalling.

I hate allen bolts. Factory torque spec is 22 ft lbs on the hinge bolts. I figured that is what I'll set these allens too. NOPE. They all were rounding off probably around 15 ft lbs. That is with me using a high quality 5mm allen socket, not a rounded ball type either. The socket fit so well that I had to knock it out of each bolt to remove the socket.

I wish Barnes used strong fasteners.

Next up was the Mabbett Fuse Box Cover. I like it. It fit really well. You cannot run any wires to the fuse box with the factory lid.

Fingers crossed the last item on my build for a while will be A pillar ditch lights. I have some RCI brackets in the mail. I'll go with Harbor Freight lights.

 

[KRAKEN]

I thought about using different bolts to install my Barnes tailgate reinforcement but didn't realized how crappy the allen bolts were until torque time like you mentioned. Also you are right about the cardboard shims to retain alignment. My small gap on the handle side of the tailgate got worse and now I need to do a full tailgate realignment.

 

[Snacktime]

I need that fuse box lid to clean up my install.

 

[Aonarch]

I thought about using different bolts to install my Barnes tailgate reinforcement but didn't realized how crappy the allen bolts were until torque time like you mentioned. Also you are right about the cardboard shims to retain alignment. My small gap on the handle side of the tailgate got worse and now I need to do a full tailgate realignment.

I bought M8x1.25 65mm studs to replace these allens. I'm going to use red locktight on the studs into the door, then blue on the nut.

I need that fuse box lid to clean up my install.

I hacked up the OEM lid, but was not happy with it.

 

[Aonarch]

I thought about using different bolts to install my Barnes tailgate reinforcement but didn't realized how crappy the allen bolts were until torque time like you mentioned. Also you are right about the cardboard shims to retain alignment.
My small gap on the handle side of the tailgate got worse and now I need to do a full tailgate realignment.

t.

My tailgate definitely shifted to the drivers side a bit. I'll try re-aligning it when I install the studs.

 

[userdude]

t.

My tailgate definitely shifted to the drivers side a bit. I'll try re-aligning it when I install the studs.

I like those rims.

 

[Aonarch]

This should be the last modification for a while.

RCI Ditch Light Brackets plus Harbor Freight ROADSHOCK 3 In. LED Spot with Side Lights.

 

[Aonarch]

Installed a cargo net. Just a random Amazon one. Should be good for light stuff.

 

[Aonarch]

That is it for mods for a while.

I am leaving Friday on a big 6,000 mile roadtrip, which is what I built this Bronco for.

We will be hitting a few national parks and overlanding.

 

[87-Z28]

That is it for mods for a while.

I am leaving Friday on a big 6,000 mile roadtrip, which is what I built this Bronco for.

We will be hitting a few national parks and overlanding.

Enjoy the build you have put together.

 

[Aonarch]

Camping in the Badlands.

 

[Aonarch]

Bronco did awesome on my 2,000 drive back to Montana from Georgia.

Fuel economy is shockingly good for RTT and max payload. 2.7l is a beast.

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