BOSS Bronco Build - 2 Door BaseSquatch 2.7

[Boss Broncos]

Background:

BOSS 4x4 was founded in 2013 and is an online off-road parts retailer that is dedicated to providing a large selection of quality parts, matched with the best customer service around. We have over two decades of experience in the off-road industry.

We are currently working on our own product line. We specialize in purpose-built products designed to handle off-road abuse with a former world champion rock crawler as an integral part of our design team... all designed and made in the USA!

We are posting our build to showcase the parts we choose for our Bronco build, providing installation tips and giving our review as well. We will also post a re-cap of events we attended too.

Day One:
9/30/22

Waited 26+ months!
2 Door Base Model - added Sasquatch Pkg, 2.7L, roof rack, and Ford all-weather mats.

Current Status:

Follow along as we add to this thread! Feel free to ask questions too.

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[Boss Broncos]

First mod:

Window tint and graphics by Rapid Wraps & Tint in Hemet, CA.

Pictured at the Nevada Bronco Off-Rodeo Oct. 2022

Same trip we also went to Toquerville Falls in Utah to get 'er dirty:

Also the first time flat towing:

We used the Blue Ox Alpha 2 system with base plates for the stock plastic bumper, and we also installed the Curt wiring kit for non-LED taillights, as well as a Curt receiver hitch for the back to load the bike rack.

I can provide more details on the components if need be. We have since changed out the front bumper and have removed the base plates, opting to use adapters for the recovery points instead (more info to come). The base plates had protruding tabs for the safety chains that got bent up easily.

Here is where we ran the wiring to in the front (behind the removeable black plastic box), 4-pin connector with excess wiring zip tied.

 

[Boss Broncos]

Nov 2022:

Trip to Ocotillo Wells for Thanksgiving.

Explored the Wind Caves

2nd time flat towing (you can see the tow bar plates sticking out). We hit Blow Sand Hill Thanksgiving night. Went right up without airing down the tires! Nice to have windows in all the dust! Discovered we needed a good whip mount and rear lights.

 

[Boss Broncos]

Feb. 2023

Went to King of the Hammers. Booked a spot at the Bronco Nation basecamp, but didn't stay there due to being sick. Stayed in an RV park in Joshua Tree for some peace and quiet!

Did a run to Bronco Knoll! We've been going to Johnson Valley for many years and would like to organize a Bronco run there soon on the Fissure Mountain trail. We have previously participated in many other trail runs there including Claw Hammer and Aftershock in IFS rigs.

Saw a good friend there who raced this Bronco in the Rebelle Rally - Tori Bundrant.

Her dad, Jon, is a legend in early competitive rock crawling, taking home numerous wins back in the day:

I learned from one of the best working at All-Pro! And his spotter too - Larry McRae who once owned Poison Spyder.

 

[Boss Broncos]

Feb 2023 continued

Joined Pacific Coast Broncos at the Bronco Stampede that started at the base of Idylwild, up to Thomas Mountain, and through Anza to Old Town Temecula and Peltzer Winery.

Great turn-out. Not a difficult trail, but did get muddy!

Only mod this month was adding the KC Slimlite Ditch Lights, and the ACC Trigger Controller since we missed the Aux Switches when we ordered! We went with the KCs for a retro look and the ACC controller made wiring easy, with remote switches so no need to run wires through the firewall. Only thing we added was a mini fuse splitter to tie it into the fuse box to an ignition controlled fuse (I think we used the USB charging port fuse).

We developed low profile, more secure mounts with countersunk bolts for a smooth finish!

We originally were going to use Diode Dynamics lights, but liked the look of the round KCs with the Bronco's round headlights.

 

[Boss Broncos]

More Feb into March 2023...

Trip to Utah for ski week towing the Bronco. Ended up leaving the motorhome and driving the Bronco back to So Cal due to all the snow! Went back 3 days later for the United by Bronco event.

This is south of Las Vegas on the 15 Fwy:

United by Bronco was a blast!

Here's our highlight video:


Stock rear bumper damage on the Toll Booth obstacle with some red rock souvenirs!

Still didn't have rock sliders, but did get some pinch weld guards on:

Countersunk black zinc plated bolts for a smooth finish and corrosion resistance. They wrap underneath for some added protection.

We also had these cup holder inserts made for event give-aways!

 

[Boss Broncos]

Apr 2023

Battle at Primm to help Team Frisby with their races. They are fellow Bronco owners!

Bronco out racing too!

 

[Boss Broncos]

May 2023

Bronco Safari in Moab UT was epic!
Towed the Bronco there!

Swapped out the stock plastic base front bumper for a 4WP bumper ($500 scratch & dent special!) The Rigid fog lights cost almost as much as the bumper!

Day 1 - Hells Revenge:


Day 2 - Steel Bender:


Day 3 - 7 Mile Rim Ladies Run:


Also added custom PRP Seat Covers:

Fully customizable! You can pick the colors, materials and stitching! Perfect fit and high quality. We opted for marine grade vinyl outer with suede in the middle seat area. It was easier to install by removing the seats.

 

[Boss Broncos]

More to come!

 

[Broncotrax]

Very cool!! Thanks for sharing!

 

[Ford Motor Company]

Apr 2023

Battle at Primm to help Team Frisby with their races. They are fellow Bronco owners!

Bronco out racing too!

How cool! Thank you for sharing!

 

[Boss Broncos]

May 2023

Trip to Calico near Yermo, CA to test a new product and meet up with Dusty & Steph of So Cal Broncos in their white 2-door base Chanel!

The new product we installed was our BOSS Walker Link System:

This is a game changer for added wheel travel and a smoother ride! Less 3-wheelin'!

 

[Boss Broncos]

June 2023

Big Bear Bronco Bash!

Continued testing the BOSS Walker Link System.

Friday - Ladies run

The "Squeeze":

Saturday - Gold Mountain run

Plus lots of cool OG Broncos at the event BBQ, here's a few:

Highly recommend this event!

 

[Boss Broncos]

Aug 2023

Back to UT to test fit the BOSS Walker Link System on a Badlands and to get some action videos at Sand Hollow!

Again, flat towing the Bronco. Had to stop at one of the original Del Tacos in Barstow!

As you can see in the pic above, we now tow from the bumper's shackle mounts using these adapters:

Use the 7/8" for the 4WP bumper. We mistakenly got the 1" and had to drill it out, which wasn't fun and required an expensive drill bit!

We retained the factory recovery points to use as safety chain attachment points since they were compatible with the 4WP skid plates we added:

Wish we would have added the front skid sooner since we bashed in the lower control arm pivot brackets. We are working on a fix to strengthen the LCA mounts.

Installation of the BOSS Walker Link system on a Badlands:

Videos of it in action:
30 second clip:


Longer video:


Top of the World!

Lunch break at the Lake!

 

[Boss Broncos]

Sep 2023

Made a Panhard Relocation Bracket to correct the geometry of the rear Panhard/Track Bar on lifted applications, including Broncos with the Sasquatch pkg.

Testing the clearance in our driveway!

Stuffed rear tire, and plenty of clearance to the frame:

Besides the custom license plate and bracket, we also added a matching 4WP rear bumper and side steps:

Reviews on 4WP armor:
Front bumper
Pros: great approach angle, solid recovery points, flush light mounts, doesn't block air flow, price, tubular hybrid styling, optional winch mount (which we add later)
Cons: needs added brackets to adequately tie into frame
Rear bumper
Pros: tubular hybrid styling, high clearance, flush light mounts, solid recovery points that tie directly into frame, compatible with hitch
Cons: didn't like license plate mount for the spare tire, a little hard to adjust alignment (we still need to tweak it some more)
Side steps
Pros: price, functional step
Cons: seem a little short lengthwise, would not be suitable as a "slider" (we will be removing them before off-roading)
Skid plates
Pros: price, good design in being high clearance and bolts protected, access panel
Cons: we did dent the front skid a bit, so it could maybe use some added reinforcement, no fuel tank skid (but we have the factory fuel tank skid)

For the license plate mount, we went with the DV8 relocation bracket for a cleaner look than the spare tire mounted kit that the rear bumper came with. The DV8 bracket was easy to install, however, we do not like how it digs into the stock Sasquatch spare tire.

We later saw Lobo Off-Road's bracket and will likely switch it out, but it is pricy. It mounts in place of the "Ford" logo.

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