Bronco Part Case Study

A local business restoring classic Ford Broncos

 

 

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Problem Bronco Frame - Steering box failure

A Bronco frame ready for updating – from a previous fram repair that failed.

The Problem

Stress fractures and failure within the original factory frames can cause steering instability or catastrophic failure of the steering box mounting points.

The Challenge

Classic bronco frames were manufactured by hand, making each frame was slightly different every time they made them.

To repair the issued they were using a bracket that required added drilling and grinding to fit within the location, either to reinforce the frame or to mount alternative steering boxes. The plate was designed to fit on one side of the frame rail only. This design process required many adjustments and even further modification to fit on the opposite side of the frame rail.

The Design Process

CAD sketch of Bronco Bracket

A preliminary sketch of the bracket, created in Fusion 360, CAD – computer aided (CAD) design software.

3d rendering of Bronco Bracket

A 3D rendering of the bracket, created in Fusion 360, CAD – computer aided (CAD) design software.

Bronco Part Prototype

A prototype for testing and cutting. Cut on our 5×10 table using a Hypertherm CNC Plasma.

Bronco Bracket Frame steering custom build

A test fitting of the Plate – Prior to welding.

Bronco Bracket Frame steering custom build

A welded plate – ready for steering controls.

Our Solution

We recognize the importance of getting products to market. So, we worked one-on-one with the client to recreate the bracket. 

We utilized computer aided (CAD) design software to recreate their product and test the probability of functionality of the prototype. We stepped through some variations of a few frames, cuts, and welds to get the bracket just right.

In conclusion, we created a custom bracket that not only fits on both sides of the vehicle frame but has additional mounting points for multiple steering box options.  The design changes increased efficiency while decreasing labor time in production.

LET'S CONNECT

Interested in Control Solutions Group Metal Fabrication Service?