See the Ingenious Engineering That Lets 40s Fit a Factory Bronco II Body

When Jeff from Omaha decided he needed a serious off-road project, he knew exactly who to call. After watching countless YouTube videos from the Bronco community and connecting with builders through online forums, he found himself shipping his 1984 Bronco II to Michigan for what would become one hell of a transformation.

This isn’t your typical weekend warrior build. Jeff’s ‘84 Bronco II started life as a $2,500 non-runner from Oregon, but that original factory paint scheme was too rare to pass up. The yellow and orange combo might sound questionable on paper, but seeing it in person will make you a believer. Sometimes the best builds start with the most unexpected foundations.

The heart of this beast is a 5.3 LS swap backed by a 4L60E transmission and NP241C manual transfer case. The builder went full send on the drivetrain, matching it with full-width axles pulled from a late ’70s full-size Bronco - a Dana 44 up front and Ford 9" out back, both running 4.56 gears. That high-pinion 9" with its removable third member opens up a world of aftermarket support that makes Ford 8.8 owners jealous.

The suspension setup is where things get really interesting. This truck runs a triangulated four-link rear with long-arm front suspension, giving it 14 inches of travel out back and 12 inches up front. Those ORI struts handle the dampening duties while a TK1 anti-rock sway bar keeps everything planted. The whole front end got moved forward two and a half inches compared to a typical solid axle swap, thanks to some creative engineering with an early Super Duty pitman arm.

Rolling on 17x9 Dirty Life beadlocks wrapped in 40-inch rubber, this Bronco II sits on a two-inch body lift that somehow manages to clear those massive tires without butchering the factory wheel wells. That’s the kind of attention to detail that separates the pros from the weekend warriors.

The build quality shows in every detail. Barnes 4WD supplied most of the brackets and DOM tubing, while Ruff Stuff Specialties handled the high-steer arms. RCV axle shafts up front pair with Reid Racing knuckles, and the whole steering system gets help from PSC power steering and ram assist. Even the brake system got the full treatment with a Hydro Boost setup and upgraded calipers.

But all the best parts in the world don’t mean much until you put them to the test. After months of fabrication and tuning, Jeff made the trip from Nebraska to Holly Oaks Off-Road Park in Michigan for the truck’s maiden voyage in the dirt. Keep in mind, this guy hadn’t been off-roading since he was 16 years old, and here he was about to tackle technical terrain in a brand-new build.

The results speak for themselves. Even without the rear ARB air locker plumbed up, this Bronco II walked through obstacles that would challenge much more experienced rigs. The combination of that long-arm suspension, proper gearing, and massive contact patch from aired-down 40s kept all four corners planted through some seriously gnarly sections.

Watching Jeff navigate his first real off-road experience in decades is pretty inspiring. The truck’s stability and capability gave him confidence to tackle progressively harder obstacles throughout the day. By the end, he was crawling through rock gardens that would make plenty of seasoned wheelers think twice.

The only hiccup? A loose hose clamp that caused a minor fuel leak - hardly worth mentioning on a shakedown run. When that’s your biggest problem on a brand-new build’s first outing, you know everything went right during the fabrication process.

This build represents everything that makes the off-road community special. Jeff connected with builders through online forums, trusted them with his vision, and ended up with friendships that’ll last longer than any truck. The collaboration between Dan’s fabrication skills and Brian’s electrical expertise created something that’s way more than the sum of its parts.

The truck still needs a few finishing touches - front and rear bumpers, interior work, and getting that rear locker plumbed properly. But the foundation is absolutely solid. This Bronco II proves that with the right combination of quality parts, skilled fabrication, and attention to detail, you can build something that performs way above its weight class.

Jeff’s planning to take this thing home to Nebraska and finish the cosmetic details, but the hard work is done. He’s got a rig that’ll handle anything he can throw at it, and more importantly, he’s got the confidence to actually use it. Sometimes the best builds aren’t about building the most extreme machine possible - they’re about building exactly what you need to get out there and have fun.