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Old 02-25-2013, 03:15 PM
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Default Supercharged 6.9 idi Diesel Bronco Build Thread

(If anyone runs across this thread in a search you can also see the build on FTE)

http://www.ford-trucks.com/forums/11...ld-thread.html

I have my bronco in the driveway again, now that I got some things moved out of the way. So it's back to my supercharged diesel f350 bronco project. Some of you know about the TVS Magnacharger I bought for the engine last year, I hope to get that mocked up and get the intake together first and then I'll start doing some suspension work that I put off two years ago. The plan is to get 12psi@3300 RPM starting out. That puts me in the max efficiency area of the TVS flow map without over boosting at idle.

This is a general idea of what I have done with the project so far and what I plan to do within the next few months.

Frame: Shortened 1984 F350 diesel 2wd ext. cab
Bumpers: Heavy channel box rear, what was left of frame front
Body: 1986 Bronco
Axles: 1988 F350, 4" lift, Dana 60 front w/custom coils+radius arms, limited slip 10 1/4 rear w/leaf springs
Engine: 1986 F350 6.9 idi diesel, complete rebuild stock CR, stock other than head studs Stan's chrome headers
Transmission: 2003 Superduty 4r100 w/Baumann controller
Transfer Case: Borg Warner 1356
Gas tank: 38 Gallon

What's up next.

Build intake or adapter for supercharger
Bolt in UMP cold air intake
Install performance reground TYPE4 cam
Convert front of motor to serpentine pulleys
Fox external reservoir racing shocks
Heavy sway bar
Rear shackle reversal
Dual electric radiator fans
Triple clutch torque convertor
Electric fuel pump conversion
Modified plastic bed liner
2.5" dual exhaust w/Magnaflow muffler


Eventually when all this is done I's sure to install some kind of intercooler. And of coarse you know something has to be done about the sound system, need some good camo seat covers and a decent paint job. Definitely need some better tires down the road. Below are some picks of the parts I have so far and of some of the work I did years ago to the bronco. Unfortunately most of the bronco pics were lost with my last computer.
Attached Images
File Type: jpg IMAG0002.jpg (89.3 KB, 9 views)
File Type: jpg IMAG0005.jpg (85.4 KB, 9 views)
File Type: jpg IMAG0007.jpg (81.7 KB, 9 views)
File Type: jpg IMAG0009.jpg (85.3 KB, 9 views)
File Type: jpg IMAG0010.jpg (86.6 KB, 9 views)

Last edited by rembrant88; 03-26-2013 at 04:58 PM.
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Old 02-25-2013, 03:19 PM
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Some more of the bronco on a hunting trip.
Attached Images
File Type: jpg tIMAG0010.jpg (97.4 KB, 9 views)
File Type: jpg tIMAG0008.jpg (91.0 KB, 8 views)
File Type: jpg hunting and bronco project 006.jpg (92.7 KB, 8 views)
File Type: jpg hunting and bronco project 008.jpg (92.1 KB, 8 views)
File Type: jpg hunting and bronco project 007.jpg (94.8 KB, 9 views)

Last edited by rembrant88; 02-25-2013 at 03:26 PM.
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Old 02-25-2013, 03:23 PM
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Some parts ready to go on.
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File Type: jpg DSCI0006.jpg (91.1 KB, 10 views)
File Type: jpg DSCI0007.jpg (93.8 KB, 9 views)
File Type: jpg DSCI0009.jpg (93.6 KB, 9 views)
File Type: jpg tvs 001.jpg (89.5 KB, 13 views)
File Type: jpg hunting and bronco project 009.jpg (86.0 KB, 11 views)
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Old 03-26-2013, 02:14 PM
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Green line is about where I will be at with 12psi@3300rpm. I should be in the TVS's 70% efficiency zone throughout most of the rpm range. Red is where I would be at 15psi@3300rpm. This engine is starting out non intercooled, so I want to keep it at the highest boost possible while still maintaining maximum efficiency. I'm waiting for a ford mustang intended Metco 10" crank pulley to arrive so that I can have a hub custom machined for it and my idi's harmonic balancer. The 10" crank pulley will help me avoid slip with a 6 rib belt while easily running the boost required. We will see what this gets me with the "Torque cam" and a maxed out stock pump. Because my fuel is being burned independent of boost, not being turbo, I'm starting out with a stock pump and injectors before going for more fuel delivery such as with the DB4 injection pump. The intake I have decided to make out of stainless steel for strength and rigidity, I don't feel like welding aluminum right now anyway.

I got the cam in. Everything else is waiting on the arrival of that crank pulley. After that gets here and I have the piece machined I can get the supercharger intake built and get the idler pulleys and belt situation taken care of. Until then I'll take care of the shackle reversal and start getting my fox shocks bolted up.
Attached Images
File Type: jpg R2300101608MAGNUSONHOUSING_CFM-vi.jpg (63.2 KB, 6 views)
File Type: jpg eSCI0005.jpg (96.5 KB, 6 views)
File Type: jpg fSCI0007.jpg (90.8 KB, 5 views)
File Type: jpg bSCI0008.jpg (93.5 KB, 5 views)
File Type: jpg kSCI0011.jpg (93.2 KB, 5 views)
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