A Wild Ford Bronco Build: 750 Hp Cummins + 2 1/2 Ton Axles + 43s = Insanity

When Westen Champlin handed over a twin turbo Cummins-swapped ‘79 Ford Bronco, the Grind Hard Plumbing Co crew knew they had something special on their hands. But turning this already wild build into a proper mega truck? That meant taking everything to the next level with military axles, custom four-link suspension, and enough fabrication work to make even seasoned builders sweat.

The project started with a simple premise that quickly became anything but simple. Westen’s Bronco already packed serious heat with its 12-valve Cummins sporting compound turbos, but the crew needed to build a drivetrain and suspension system that could handle 750 horsepower on extreme terrain. That meant ditching the factory setup entirely and going full send with two-and-a-half-ton Rockwell axles from Western Canadian Rockwell.

Building a mega truck in a driveway isn’t exactly standard operating procedure, but the crew made it work with some seriously creative engineering. The sketchy-but-effective lifting system they rigged up using reinforced jack stands and a skid steer had everyone holding their breath, but it got the job done. Sometimes you’ve got to work with what you’ve got, and redneck ingenuity paired with proper engineering can produce some impressive results.

The fabrication work on this build was next level. Custom four-link suspension with massive inch-and-a-quarter heim joints, DOM tubing thick enough to use as a baseball bat, and shock mounts that could probably hold up a small building. Every piece was designed to handle the punishment that comes with running a built Cummins through serious terrain. The attention to detail shows - from the hexagonal cutouts in the brackets to the proper thread engagement on every joint.

Getting the hydraulic steering system dialed in required completely rethinking how steering works on this rig. The orbital valve setup means no more mechanical connection between the steering wheel and the axle, which makes packaging way easier when you’re dealing with this much suspension travel. The power steering pump got relocated and the whole system was sized to match the engine RPM and steering ram requirements.

The brake system upgrade was equally impressive. Those massive disc brake conversion kits from Western Canadian Rockwell meant saying goodbye to drums forever. When you’re running 43-inch Mickey Thompson tires and have this much mass to stop, you need serious stopping power. The calipers alone are the size of your head, which gives you an idea of the scale they’re working with here.

First startup after all that work is always nerve-wracking, but hearing those twin turbos spool up made it all worthwhile. The initial test drives revealed exactly what you’d expect from a mega truck - tons of body roll, incredible ground clearance, and enough torque to climb anything you point it at. Sure, there was some tire rub to sort out, but that’s what plasma cutters are for.

The suspension setup delivered exactly what they were after. Twelve inches of travel front and rear, with coilovers and bump stops all properly positioned to work together. The four-link geometry keeps everything tracking straight while allowing for massive articulation. It’s the kind of setup that makes technical terrain feel like a parking lot.

Taking the finished truck straight to the Rubicon for its maiden voyage was the perfect test. This isn’t some mall crawler - this thing was built to handle serious terrain, and the famous trail provided exactly the right proving ground. Watching it climb obstacles that would stop most rigs dead in their tracks shows just how capable the finished product turned out to be.

The collaboration between Westen Champlin’s engine work, Grind Hard’s suspension and drivetrain fabrication, and Lacey Blair’s finishing touches created something truly special. This isn’t just another engine swap or suspension upgrade - it’s a complete transformation that turns a classic Bronco into a modern mega truck capable of handling anything you throw at it.

From the compound turbo setup breathing through those massive intercoolers to the military-grade axles riding on beadlock wheels, every component was chosen and built to work together as a system. The result is a truck that looks absolutely wild but backs up its aggressive appearance with serious capability.

The build process showed exactly what’s possible when you combine proper planning, quality components, and the willingness to do whatever fabrication work is necessary to make it all work together. Sometimes the best builds are the ones that push every system to its limits while maintaining the reliability needed for serious wheeling.

Check out more builds and behind-the-scenes content at grindhardplumbingco.com, and follow along on Instagram and Facebook for the latest projects and adventures.