Build Thread – Hot Sauce the Full-Size

We are gearing up to convert this beautiful 1996 Bronco from the factory twin traction beam setup to a solid axle front end. While we are under the truck we are going to keep you updated on the install and the cool stuff we have in store for this build. This Eddie Bauer edition came in to be part of the film series covering all the goodies we offer for the Full-Size Bronco on Bronco Garage. It’s in great shape and has definitely been taken care of for the past 24+ years. We dubbed it “Hot Sauce” it features a built 5.8 with a Holly Sniper EFI installed, and a great sounding exhaust. It currently has a leveling kit on the truck and the owner uses it to tow his toys to the various parks around Tennessee for recreational use. We are going to take you through all the Levels of our solid axle conversion as well as answer any questions you may have about completing this build on your personal Bronco.

For this Full-Size Bronco, we will be installing the owner supplied High Pinion ’78-’79 Big Bronco Dana 44 front axle and Sterling 10.25″ rear axle from an early 90’s F-250. The wheels are chrome Hostile 20″ with 13.50″ Toyo Open Country A/T tires. Both axles are configured with Disc Brakes and have 8-lug hubs. Bronco Garage plans to have videos to give you tips on what axles you should consider swapping under your Bronco when swapping from TTB and supply you with tips and tricks of installing the complete Monster Package SAS swap in our Midnight Black Finish.

8/5/2020: Today we took the Bronco around the block to shake off the cobwebs and stretch it’s legs since it’s going to be put on frame stands for the next month or so. We also did some measuring of the stock suspension for droop and travel so we can compare those measurements after the straight axle conversion has been completed. Here’s a few pictures.

Have a question about this build or swapping in a solid axle in your ride? Leave a comment below and we’ll get you an answer. Maybe it’s something that needs to be covered in a video? You can also share your advice too! We look forward to bringing you updates as they happen.

About James Duff: Bronco Experts since 1967, James Duff is a name synonymous with the Ford Bronco. Always evolving and taking our product to the next level. Our ’80-’96 Full-Size Bronco and F-Series SAS systems will take your Bronco from Mild to Wild. We also carry a wide variety of parts and accessories for the Classic ’66-’77 Bronco. Learn more about James Duff and our Journey over the past 53 years here.