BOSS Bronco Build - 2 Door BaseSquatch 2.7

[lapazleo]

The original 1969 1 of 1 Boss Bronco prototype. Was supposed to have been destroyed when it didn't go into production. Some how it wasn't and belongs to a collector.

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[Boss Broncos]

The original 1969 1 of 1 Boss Bronco prototype. Was supposed to have been destroyed when it didn't go into production. Some how it wasn't and belongs to a collector.

So cool! We are going to change our graphics to be closer to the original "Boss Bronco".

 

[Boss Broncos]

Sep 2023 continued

We went to the Off-Road Expo in Pomona, CA.
Meet a few other Bronco owners at the donut shop before heading into the show:

Some of our favorites:

These Anderson Composite fenders will be in our future! Love the shape!

One more mod this month:
FrontRunner tailgate table:

We made a quick installation video since Bronco specific instructions were not included.

 

[Boss Broncos]

Oct 2023

Got a small cargo trailer to take products to the Bronco Super Celebration Neveda in Carson City:

Towed great expect for all the gas stops!

Left the trailer on site and headed out to sight see and run a trail!

Group hike to the Kings Canyon waterfall.

First time at the Prison Hill OHV area. Some good trails there!

As you may have noticed, we added a TJM awning for the show for shade:

The arrows point to the mounting brackets on the underside of the stock roof rack. We removed the rack and used self tapping low profile screws to attach the brackets. We opted for the smallest size TJM awning with our 2 door. It fits nicely on the rack with no overhang.

 

[BroncoMan24]

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.

Where did you get those decals? Looks good! I’m getting same KC and some rigid fog lights soon. How’s been with the Wireless Trigger controller so far? I know nothing about mechanic, electric nor cars! So really curious how am I gonna do it once I get the lights, more because I do not have Aux switches like you. Thanks for sharing.

 

[Boss Broncos]

Dec 2023

Decided to finally install a winch, which meant a suspension upgrade as well to handle the added weight.

We originally tried to install a Mean Mother Winch but it was too large and hit the hoop, so we opted for a Smittybilt to ensure it would fit with the 4WP bumper and it has great features and performance specs.

This is the plate needed to mount the winch:

And this is the winch we went with - 9.5k-lb. Smittybilt XRC Comp Series Gen 3 Winch with Synthetic Rope

We ran the cables up through the center of the grille where there's a hole by the hood latch, then over to the battery. Spooled the rope by attaching it to another vehicle and pulling the Bronco to keep tension.

With all the added parts, we needed to upgrade the front suspension. We used Bilstein 6100s with the stock Sasquatch coils at the 4th notch setting to keep it level with the rear.

Before:

During:

The Radflo Jack was such a big help! That's our 17 year old son getting his hands dirty!

After:

Besides the 6100s, we also changed out the UCAs and Tie Rods. We hadn't planned to do the UCAs, but since we accidently punctured the stock ball joint boot, and had a set of 4WP arms on hand, it was an easy fix. The Icon Tie Rods we've had for a while as a trail spares, but decided to swap those in before the alignment.

A spring compressor is needed to unassemble and re-assemble the coilovers.

 

[Boss Broncos]

Where did you get those decals? Looks good! I’m getting same KC and some rigid fog lights soon. How’s been with the Wireless Trigger controller so far? I know nothing about mechanic, electric nor cars! So really curious how am I gonna do it once I get the lights, more because I do not have Aux switches like you. Thanks for sharing.

Beautiful Bronco!

We got the decals from Rapid Wraps: Wraps, Tint, & Auto Glass in Hemet, CA - Rapid Wraps & Tint (rapidwrapsandtint.com) He has the file still so can duplicate them for you including the hood (and obviously without the wording! lol)

The Trigger Controller has worked great so far! Great solution for those of us that missed getting the Aux switches. As I mentioned in the post, we did get a splitter to attach it to an ignition controlled fuse so that it doesn't draw power constantly. Here's what the switches look like inside:

We got the 4-switch controller, but there is a 6-switch version as well.

 

[BroncoMan24]

Looks awesome! Thanks again for sharing! I’ll get it then!

 

[Boss Broncos]

A few more additions:

Used our Ford points to get the rear cargo mat. And got some rear seat back protectors off Amazon that work with both the stock seats and the PRP seat covers. Our pup loves to ride along, so it helps keep his hair from sticking.

We also have a Mean Mother recovery kit and compressor, and a TJM multi-tool shovel. We often carry a set of Exitrax 930 recovery boards as well, along with a TJM tire repair kit.

 

[Boss Broncos]

Looks awesome! Thanks again for sharing! I’ll get it then!

We sell them here: Advanced Accessory Concepts '21+ Ford Bronco TRIGGER Switch Combo Kit, 4 or 6 (boss4x4.com)
and offer free shipping! If you have any questions during the install, let us know!

 

[userdude]

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 1" for the 4WP bumper. We mistakenly got the 7/8" 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!

Are those videos of the BL Walker links with the disconnect turned on?

 

[Boss Broncos]

Are those videos of the BL Walker links with the disconnect turned on?

No, the videos capture standard sway bar. I do have this clip showing the BLs sway bar as it is disconnected after installing the links.

 

[wigglysqiggly]

how do you like the 6100, tempted to get some but not too sure if worth it

 

[Boss Broncos]

how do you like the 6100, tempted to get some but not too sure if worth it

We sell a lot of 6112s for other applications and know they are a quality shock. So far it seems the ride quality is the same as with the stock Bilsteins (which I thought wasn't bad), except that a little more body roll is noticable but that is to be expected with a higher center of gravity and added weight from the winch. Haven't been off-road yet though. We installed them with the Sasquatch coils, but may swap those out for the Bilstein 6112 coils to see it there's any change. It's also tempting to just throw on the 4WP coilovers since they are a better value and cost less!

 

[mike8675309]

It's great seeing a 2 door getting all the love.

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