"The Bus" Build

[WheelMe]

Orange, hence "the bus".

This isn't exactly a "jaw-dropping"-caliber build thread, but more of a documentation of accessories that I add on to my 4D Badsquatch, requiring merely a basic level of mechanical aptitude and some everyday tools.

So far I've added some Rigid 4" ditch lights, a Ford Performance drawer system, and just this morning installed the ARB twin compressor with a KR bracket (see photos below).

Additional planned accessories include a Warn winch on an RC winch plate (Mod bumper), Baja Designs fog lights, a low-profile rear bumper with improved depart. angle, ham radio antenna system, and finally a soft-top roof rack system when those become available. I'll add photos as I install these items. For now, some pics:

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[Ground_zero298]

Very nice!

 

[WheelMe]

I've been adding a few items here and there, and will post pics ASAP. Some of these items include:

4x4 TruckLED's Baja Designs foglight kit
Trailgater tailgate drop-down table
Rokblokz front mudflaps
Bilstein 6100 shocks for a 2" lift (yet to be installed)
Rough Country HD Mod bumper mount + Warn EVO 10S winch (yet to be installed)
ASFIR Cross member skid covers (these were made known to me by a fellow forum member - I'll update with his handle shortly)

The mod that I'm most excited about are the ASFIR cross-member skid covers, as my cross members get bashed each time I go wheeling (here's a link if folks have no idea what I'm talking about: https://www.asfir.com/skid-plate-599662.html). Made in ISRAEL - to boot!

More soon.

 

[WheelMe]

More stuff ordered and coming (There's nothing more fun than spending money):

IAG rock slider steps
Soft top hydraulic lifts
Rocker protection film

I'm in the middle of installing a Warn EVO 10S onto THE BUS' MOD bumper, using the RC mount. I must say that the mount's isn't pretty - the welds are ugly and the pieces are rough looking; some bolts are missing as well. Overall, though, it's a good design, and not hard to put together - excellent installation instructions, by the way.

Despite a good design, they can't possibly accommodate all the winches that are out there - one example being my Warn EVO. The body of the EVO juts out so much that the RC-included proximity sensor locking plate won't fit, despite any amount of grinding - I'll have to come up with my own solution to keep the sensors from falling out of the mount holes... not a big deal.

Some initial photos below - I'll post more when the job is completed.

THE BUS with a big smile, awaiting his new winch.

The mess of wires go to the Baja Designs fog/spot lights clusters in the bumper.

This piece is attached to the inside of the bumper by four bolts; the entire bumper is then attached (through the two holes seen here (plus one on the other side of the tow point) to the Bronco's chassis, seen in the previous photo. This is a beefy piece.

The winch is now bolted to the mount. I've removed the control box from the top of the winch; it'll be relocated to the engine compartment (probably using a BAMP bracket) so as not to block the BRONCO lettering on the grille. In terms of the camera, I'll be installing a JCR camera relocation kit in order to retain that capability, which I've found very useful while cresting a hill, or threading through boulders that I can't see from the driver's seat.

 

[BroncoSarge]

It’s WAY easier if you mount the bottom half to the bronco first. Then attach the top plate, winch etc. I learned this on my second install.

 

[WheelMe]

It’s WAY easier if you mount the bottom half to the bronco first. Then attach the top plate, winch etc. I learned this on my second install.

Lol, I wish that I'd thought of that, which would've saved the entire family some muscle - it took all three of us to hoist the monstrosity up to the bumper and bolt it on). In any case, the "Bus" now sports an awesome winch, though it's not electrically hooked up yet - I need to order some extension cables for the control box.

At first, the proximity sensors errored out, but with a bit of wire-jiggling, they started working properly - hope it stays that way. I also noticed that the steering feels heavier while maneuvering in a parking lot - the extra 80 lbs. is taking its toll. I forgot to measure how high the front sat before the winch install - it might have lost 0.5"; luckily, I have some Bilstein 6100 shocks coming, which should bring the height back up.

It looks pretty good, in my opinion. "Hey Jeep Guy, need me to winch you out?!"

 

[BroncoSarge]

Gotta run those cables in back. You can tuck them between the bumper and the body color piece. i also removed our decals and blacked out the chrome.

 

[WheelMe]

That's the plan - the black negative cable is tucked around the winch temporarily till my extended cables arrive. One thing I haven't done yet is trim the bumper covers - what tool did you use to trim yours? I'm thinking of using my dremel with a cutting wheel.

 

[WheelMe]

Fun times ahead (just Forscanned):

 

[WheelMe]

The Israeli cross-beam armor has arrived - stainless steel, very well-made. I'll get these installed after I grind off the rust on the cross-beams and repaint them.

Blue skies today.

 

[WheelMe]

Slowly but surely... relocating the winch control box and installing the JCR camera bracket.

Warn was out of stock on the EVO 78" extended cables, but the Zeon counterpart worked just fine. Routing the cables from the engine bay to the winch, one by one, was a relatively simple task.

The grille was surprisingly easy to take off, and re-install - love how modular the whole truck is.

The Bilstein 6100s get installed tomorrow - can't wait to see the new stance, and test out the new ride height on some rocks in a couple of weeks.

 

[WheelMe]

The winch now works, and I replaced the Warn fairlead with one from Yankum Ropes - I'm ridding the winching system of metallic objects that can kill... the Warn hook is still on, but will soon be replaced with a spliced loop that hangs on either side of the new fairlead.

On another note, the ASFIR crossbeam armor has been installed - looks great and should do the job well; we'll confirm after the hitting the Deer Valley trail in CA in a couple of weeks.

Last but not least, I got my LIFT! Thanks to the new Bilstein 6100s, set at maximum height, I measure a 1.5" height increase at the CV joint... I was hoping for 2.0", but the winch system weighs 80 lbs., and brought the height back down some - the new shocks still "leveled" the rig, though, which is great. The 6100s are a noticeable improvement over the OEM SAS shocks - they're more compliant over irregular surfaces, and should much better in ruts that I'll be hitting this weekend on the trail.

Although there's now room for 37s, I won't go there in order to keep the rig's weight down and avoid added stress to suspension/steering components.

Have a nice weekend, and go wheel your Bronco!

 

[WonkyBronky]

The winch now works, and I replaced the Warn fairlead with one from Yankum Ropes - I'm ridding the winching system of metallic objects that can kill... the Warn hook is still on, but will soon be replaced with a spliced loop that hangs on either side of the new fairlead.

On another note, the ASFIR crossbeam armor has been installed - looks great and should do the job well; we'll confirm after the hitting the Deer Valley trail in CA in a couple of weeks.

Last but not least, I got my LIFT! Thanks to the new Bilstein 6100s, set at maximum height, I measure a 1.5" height increase at the CV joint... I was hoping for 2.0", but the winch system weighs 80 lbs., and brought the height back down some - the new shocks still "leveled" the rig, though, which is great. The 6100s are a noticeable improvement over the OEM SAS shocks - they're more compliant over irregular surfaces, and should much better in ruts that I'll be hitting this weekend on the trail.

Although there's now room for 37s, I won't go there in order to keep the rig's weight down and avoid added stress to suspension/steering components.

Have a nice weekend, and go wheel your Bronco!

Looking good. Made me check out the ASFIR products, and ended up ordering almost all of their underbody protection!

 

[ChompSticks]

I like that fairlead.

 

[WheelMe]

Looking good. Made me check out the ASFIR products, and ended up ordering almost all of their underbody protection!

That's awesome! I'm glad that you find ASFIR's products up to your standards. Don't hesitate to contact them during the ordering/shipping process - they're very responsive.

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