MNR 4600 class 2021 U4 Bronco build

[JR4X]

Time to kick this off. Pic for attention

After having been one of the very few teams to race an all Ford race vehicle including engine for many years. We were extended an offer from Ford motor company via Loren Healey at Fun Haver racing. We were offered the opportunity to get our hands on a pre production 2021 Badlands edition 2 door hard top Bronco with the 2.3L ecoboost and MT88 7 speed manual transmission. We didn’t ask very many questions and the whole team agreed it was to big an opportunity to pass up.

Initially we assumed we’d be getting a title with it. We were initially told we’d only have to race it 3 times and then our obligation to FoMoCo would be completed, then the vehicle would become ours. We were told that we were financially responsible to build it ourselves but that they would extend us the ability to get any of the parts at our cost already in production on the 3 other Bronco’s already built by Geiser Brothers Racing. We took their word for the deal and happily hauled it home from KOH 2022 after it spent a couple weeks on display and going on corporate test drives out in JV. This thing was also passed around to several magazines for people to test drive write articles about etc. when we took ownership of it it had 538 miles on the odometer. As of February 2022 that was all we knew before dragging it home.

 

[JR4X]

We knew we had to sign a contract with FoMoCo before everything became official so we didn’t start on anything right away. We didn’t even have any documentation saying it was ours. Not wanting to invest time and money for the deal to fall through. We just sat on it for a few months building a plan of attack while watching the already completed Broncos racing, winning, pissing people off.

We got a quote for a parts list that would make our Bronco exactly like Vaughn’s, Lovell’s,and Cole’s. That parts list included 74 weld portals, 47 spline front axle shafts, a Dana 80 rear axle, coilovers, a-arms, etc. That parts list didn’t include any labor, we had to do all the work. I can’t put the $$$ figures out on the record but it was a staggering amount of money that we just would not be able to come up with. At this point we still don’t have a contract and now we’re sweating it. If they expect us to build it like the other ones we can’t do that.

Finally early summer we get the contract and of course as we should have expected it had some curve balls. Our actual obligation would be 5 races a year for 3 years beginning at KOH 2023. After the conclusion of the 3 years we are to return the body and chassis to be crushed. We don’t get a title for it and we will make no attempt to make it street legal or drive it on public roadways. We’re on our own to figure out the electronic stuff like deleting ABS, VATS, Air Bags, Advance Trac and all the nightmare nanny computer stuff. Ford can’t help us defeat equipment required by NHTSA.

So at that point we took the top off of it, threw 35’s on beadlocks on it and started playing around with it. With the low gears the lockers, sway bar disconnects it’s actually a pretty capable little crawler.

 

[JR4X]

The first thing I gotta address is what I said I was going to do. Vs what I am now going to do instead. I already told everyone here that there was no way I could do the portals like the other guys have. If it’s any secret to any of you I’ll tell you for sure now. The 74weld portals are $10,000 dollars…. EACH! And that is NOT every part required to use them. The unit bearings and brakes are a separate cost in addition to the portals themselves. So the portals alone are in the neighborhood of $22,000 dollars all in for a pair of them to run up front.

So there they are. I said there was no way I could do it but I kinda got peer pressured into it. The reality of the situation is this. I can’t waste this opportunity with Ford. Maybe this is a one and done deal. Maybe if I play my cards right I get to keep racing with Ford factory backing. I talked myself into the portals for the fact that I need to be competitive against true professional drivers. Vaughn and Brad make their living racing. Not having portals was gonna be like bringing a knife to a gun fight. So if you’re disappointed that I already jumped the shark and went the portals route, I don’t blame ya. For the time being it seems like the right move.

Those are Spidertrax 45 spline 6 on 6 1/2 trophy truck unit bearings. These will also be used in conjunction with 45/40 spline RCV shafts with the giant CV’s everyone refers to as Rockwell sized.

 

[JR4X]

For the rear axle I’m straying from the Dynatrac Dana 80 the other guys are running. I don’t want to carry the weight and I prefer the 9” drop out style thirds. This thing is getting a RuffStuff 10” housing with a gearworks 10” third with 5.43 gears with our custom built serviceable unit bearings. 40 spline axle shafts and ours will be triangulated 4 linked instead of a panhard 5 link like the other Broncos.

 

[JR4X]

Engine management: when we were first offered the Bronco, we were told Ford would help us do whatever it takes on their end to defeat any unwanted or troublesome software. Then that turned out not to be the case. A blessing in disguise though.

So the 3 V6 Broncos have fully intact Ford electrical systems with a bunch of stuff turned off. But they still have the 100 pound wire harness end to end in the vehicle. Then they have Motec engine management systems patched together with the original Ford system making an electrical nightmare. At Sturgis Vaughn wrecked his and put it in some kind of unhappy that they can’t get turned off, at Crandon he would take 3rd of 3 vehicles because it just won’t run right anymore. It’s pulling power for intake air temp and knock retard but nothing is different from before the wreck. These little things are tight with the 2.7 under the hood and they heat soak bad.

So I got to googling. I started with the search terms “stand-alone 2.3 ecoboost” and one of the first things I found was direct from Ford. Ford performance sells a “power pack” meant to put a 2.3 with a manual trans (or auto with no sensory input) into older cars. It comes with everything needed to make a 2.3 run in like a 65 mustang. Since it’s from ford it has all the bells and whistles on the tuning side. Very simple wire harness, ECM, intercooler, MASS air sensor, DBW pedal and some other goodies. Problem solved for me only. All the other guys have the 10 speed auto which from my understanding is a pain in the ass to make work in a stand-alone setting. Right now the Fun Haver guys are trying to piece a bronco together and can’t get the pre production trans to talk with the vehicle CM and shift right. So the little 7 speed manual is going to be a way cleaner stand-alone conversion than the other guys.

I bought mine from here https://www.cjponyparts.com/ford-pe...MI8Nmll6C_-gIVGB-tBh0pdg4rEAQYASABEgJIHPD_BwE a few months ago and it was only $1600 shipped at the time. Prices have skyrocketed since.

On pump gas the 2.3 has 300 hp and 325 tq, not shabby for an extremely light little 4 banger. Mustang guys are getting 500+ hp out of these, the rally guys are getting 700 hp out of them. I’ll make it as spicy as I need to to hang with the heavy V6’s.

 

[JR4X]

Photo dump of it, this is all the pics I have of it in stock config before tear down starts. it’s basically a Lego block in every way. It’s square, same length width height and mostly a bolt on affair.

 

[Toreadorranger]

Reserved for Criticism

 

[Sterlingfire]

This should be fun!

 

[YotaAtieToo]

Portals only in the front?

If so Are they 1:1 or are you doing some fuckery to match gearing.

I assume the other 3 are running the 2.7 v6 and 10 speed auto. Are you worried at all that you'll be at a big disadvantage there?

BTW, glad to see you guys getting this opportunity. Don't forget the cheap ass zuk guys when you're sipping white claws on Vaughns yaht

 

[JR4X]

Portals only in the front?

If so Are they 1:1 or are you doing some fuckery to match gearing.

I assume the other 3 are running the 2.7 v6 and 10 speed auto. Are you worried at all that you'll be at a big disadvantage there?

It takes gear ratio fuckery. The portals are 1.45:1. I wanted to go in the 6’s for axle ratio. With the available front gear ratios the only ratio that lines up with the available high pinion rear ratios is 3.73:1 to end up at 5.40:1. I crunched numbers as hard as I could but that’s what I’m stuck with.

Portals only work up front on the Bronco because of the IFS. The rear axle doesn’t have enough up travel for portals because of frame and body clearance.

I’m always worried about advantage. Yes the 3 Broncos already running have the 2.7 and 10 speed. Those little things haul ass. I have a little bit of an advantage in weight. The 4 banger man trans combo weighs less than the bigger motor.

2.7L ecoboost and 10R80 weigh 680 pounds. 450# engine 230# trans.

2.3L ecoboost and MT88 weigh 419 pounds. 311# engine 108# trans.

We're starting off 260 pounds less than our primary competitors. Our 9 inch will weigh less than their Dana axle does to.

BTW, glad to see you guys getting this opportunity. Don't forget the cheap ass zuk guys when you're sipping white claws on Vaughns yaht

Vaughn’s handlers don’t let us get to close just yet. I can go look at his Bronco’s any time I want though. I live closer to them than he does.

 

[SLOWPOKE693]

Fawkin bad ass. I wouldn't be ashamed about buying a stupid amount of money in portals. Personally I want to see you guys kick the crap out of the "professional drivers" in the class and not giving them an equipment advantage is a good way to get that done. Your whole family is a bunch of wheelers/racers and you guys know the right people in the game, I can see great things happening with this in the future.

 

[SLOWPOKE693]

Btw.... Those portal boxes are straight CNC porn. Looking at those pictures makes my pants fit tighter. 😍 Do you sleep with them in bed next to you? I would. 😁

 

[JR4X]

Btw.... Those portal boxes are straight CNC porn. Looking at those pictures makes my pants fit tighter. 😍 Do you sleep with them in bed next to you? I would. 😁

They definitely get petted a lot 🤣. They weigh 115 pounds each. I haven’t been able to get a pic of the block of billet they have to start from but it’s not because I haven’t tried. Very precise, inside and out.

 

[Byro]

Only thing I have to add is will you please put this thing on Maxxis so I can get paid to help you guys out at the races.

 

[Poke]

Do you need race radios? I’ve got all my stuff on a shelf.

 

[JR4X]

Do you need race radios? I’ve got all my stuff on a shelf.

I do. What system do you have?

 

[Poke]

I will PM you pics. It’s a mix. My chase radio and handhelds.

 

[scooter2374]

Fuck yes. I've been waiting for this since you posted after KoH this year.

 

[Opiebennett]

So, they gave you the car that has almost no value to them (they cant sell it, and already got all the media guys use), that you don't get to own, and you have to race it 15 times in 3 years at your own cost, and build it at your own cost, but then it gets crushed.

Do you at least get to own the parts you put on it? Like keep your receipts and strip it before they come and get it? Do you have to account for all the parts you take off, like the IRS stuff?

Other than the potential for future working with Ford, I'm not sure I see the up side.

 

[JR4X]

So, they gave you the car that has almost no value to them (they cant sell it, and already got all the media guys use), that you don't get to own, and you have to race it 15 times in 3 years at your own cost, and build it at your own cost, but then it gets crushed.

Do you at least get to own the parts you put on it? Like keep your receipts and strip it before they come and get it? Do you have to account for all the parts you take off, like the IRS stuff?

Other than the potential for future working with Ford, I'm not sure I see the up side.

Upside, I get to race a brand new Bronco. You can’t even go buy one of these off the lot and I’ve had one all year.

The only thing I have to return at the end is the tub and frame. But it is a little bit of a let down. When we agreed to play the game I asked because I know some magazine guys who’ve had to return the shell to be crushed. I asked if we were going to have to give it back and the answer was no. The contract says otherwise. I’m not turning back now, we’ll see at the end what has to happen.

 

[Opiebennett]

Maybe build a custom frame and toss the OEM one in the corner, then you just have to come up with a body when it's all over

 

[JR4X]

Maybe build a custom frame and toss the OEM one in the corner, then you just have to come up with a body when it's all over

I’ve already posed the question of returning equivalent crushed weight. In 3 years I can amass a whole crushed cube of PBR beer cans for the aluminum and a frame with the vin on it.

 

[mobil1syn]

So, they gave you the car that has almost no value to them (they cant sell it, and already got all the media guys use), that you don't get to own, and you have to race it 15 times in 3 years at your own cost, and build it at your own cost, but then it gets crushed.

its actually a pretty good deal if the races are his only obligations.

portals were the right call

 

[Wilson]

Why so much beef upstream of the portals? I cannot believe the others are running d80’s or that I missed that they were, seems insane for 35’s.

Glad to see the build and the front portals are the right call. Best of luck!

 

[mobil1syn]

Why so much beef upstream of the portals? I cannot believe the others are running d80’s or that I missed that they were, seems insane for 35’s.

Glad to see the build and the front portals are the right call. Best of luck!

rears are unportaled.

im going to guess whoever is supplying the axles went all in for the aftermarket bolt in crowd.

 

[JR4X]

Why so much beef upstream of the portals? I cannot believe the others are running d80’s or that I missed that they were, seems insane for 35’s.

Glad to see the build and the front portals are the right call. Best of luck!

To make it literally bomb proof I guess. Ford engineers Spec’d the first 3. Why they went with a Dynatrac D80 is mind blowing to me. But I went and saw it myself. Vaughn’s came home from Crandon looking like a smiling face 🙂. I went and looked at it at the shop strapped to the pallet before it got sent off to whoever built it to see if it could be fixed. It’s a giant chunk of iron for turning 35’s. I think the big ass CV shafts get more angle than the smaller ones. Or maybe they didn’t know that the portals take half the strain off the axles. Or maybe it’s because that’s the size Loren’s and Vaughn’s 900 hp 4400 cars uses.

Edit: the first 3 are more bolt on than ours will be. Theirs the Dynatrac axle came tabbed to bolt into the Broncos using the factory links.

 

[Wilson]

rears are unportaled.

im going to guess whoever is supplying the axles went all in for the aftermarket bolt in crowd.

Maybe, but holy cow!

 

[Wilson]

To make it literally bomb proof I guess. Ford engineers Spec’d the first 3. Why they went with a Dynatrac D80 is mind blowing to me. But I went and saw it myself. Vaughn’s came home from Crandon looking like a smiling face 🙂. I went and looked at it at the shop strapped to the pallet before it got sent off to whoever built it to see if it could be fixed. It’s a giant chunk of iron for turning 35’s. I think the big ass CV shafts get more angle than the smaller ones. Or maybe they didn’t know that the portals take half the strain off the axles. Or maybe it’s because that’s the size Loren’s and Vaughn’s 900 hp 4400 cars uses.

Angle is the only reason that would make sense for your team.

 

[Pitbullcruiser]

Yes!

 

[YotaAtieToo]

I’ve already posed the question of returning equivalent crushed weight. In 3 years I can amass a whole crushed cube of PBR beer cans for the aluminum and a frame with the vin on it.

So what's actually aluminum on the body?

Watching Fred and Dave chop up that 4 door into a truck, all the body work I saw was steel. I was slightly surprised as I figured they'd go aluminum like the trucks.