Bronco #2 The wheeler

Got the new tires mounted today, got them home and on and they look great! Test fit the spare to see if it was going to look right where I plan to put it with the new bumper. As I was looking the front tires didn’t seem to sit right in the wheel wells. Checked the openings and they are roughly the same. As I looked closer. I guess I messed a measurement up when I was setting everything up and I’m about 3/4”1” off on one of the radius arm mounts. So I’ll be spending tomorrow cutting that out and cleaning the frame and bracket up for another pass when it’s corrected. Unfortunate and wish I had caught it sooner but it just wasn’t as obvious with the 35s. Live and learn. Submitting my bumper plans for my fab class tomorrow hoping to get started on it next week.
 

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Got the brakes knocked out today, gravity bled them enough to get the bronco pulled out of the shop and cycled to the lift bay. Gotta dial in the suspension, get everything torqued and a quick and dirty alignment. Still need to finish the radius arms welds but want to triple check the measurements before I burn it all in.
 

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Well it looks like the front axle I got for the swap is bent… I struggled getting the shaft back in but figured it was just how tight the carrier was. Got it in no big issue.figured m My measurement was off, no big deal. Well now I have a leaking axle seal and the axle is weeping gear oil from the plug welds….. frustrated and exhausted from this thing right now….feels like too many coincidences for it to not be bent. Not sure what the best route moving forward will be….any tips? Any way to know for sure? Feel free to call me an idiot. I should have looked closer. But not sure what I could have done different at the time.
 

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Need to figure out what plane it’s bent on. If it’s just a simple frown, you could anchor it and put a bottle Jack under the bend to straighten it and weld a mini truss to it to keep its shape. But that’s all in how much time and effort you want to put into it. I’d figure out how bad it’s bent before I decided on anything. see if it’s the tube or where it goes into the housing, or if housing end is cracked or whatever.
 
Need to figure out what plane it’s bent on. If it’s just a simple frown, you could anchor it and put a bottle Jack under the bend to straighten it and weld a mini truss to it to keep its shape. But that’s all in how much time and effort you want to put into it. I’d figure out how bad it’s bent before I decided on anything. see if it’s the tube or where it goes into the housing, or if housing end is cracked or whatever.
From what I’ve been dealing with, it seems like the passenger side is bent rearward. Hopefully I’ll know more this weekend after I tear out all apart and start looking at it.
 
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Started pulling the passenger side apart. Here you can see where the axle shaft is pushed towards the front of the hub. When I was installing it, I didn’t think anything of it since it moved back into place, but it has some tension on it pushing forward. Would it hurt to let this axle just leak to where it wants to be, Then wheel it in November and worry about it later?
 

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Confirmed bent AF on the passenger side. Forward and down.
 

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Well I have plans to go and get another axle on Thursday, in the meantime, back to making plans for my welding class projects. Currently planning on 2x6 sliders and a swingout tire carrier. Ordered my steel already, ordered a trail gear tire mount similar to Genright's spindle style mount, a latch similar to the ones used by EAG bumpers because I liked the one that was on my YJ, and a bumper spindle from summit machine at the recommendation of my instructor. With the 37s being so large I'm trying to keep the spare lower for weight and visibility. With that comes a couple of issues, one the tire is heavy, holding it in place to tighten the spindle on the mount will get tiring, secondly, I don't want to have any issues dropping on the tire coming off a ledge. With that in mind. I'm thinking of building a small skid under the tire to rest the tire on when loading it and glance any blows the tire would take away. The sides of the bumper will also wrap around the corner to act as a lower corner guard to protect the body slightly. I will be building a cooler mount on the end of the tire carrier and a small table on the inside that will meet up with my tailgate for a larger space for having lunch on the trails or working on stuff on the trails. Just trying to check all the boxes. I'll attach the rough drawing of my design and let me know what you think. Is it stupid or a bad idea? I don't see many people incorporating something like this in so unsure if its pointless. The tailgate will cover it when the tire carrier is open and the tire will cover the skid when it's closed so I shouldn't have to worry about running into it on accident haha. Let me know what you guys think.
 

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