The Broncast - Ford Bronco

The Broncast is BACK — and we're doing it LIVE from the garage! After a long break, Jon Melton and Donnie Whiteman welcome the newest member of the show, Matt Mooney, founder of the Tennessee Bronco Club and co-founder of Mooney Offroad. In this episode, Donnie and Matt finally reveal what they've been working on for two and a half years: an IFS chassis that puts a 2026 Gen 6 Bronco underneath a classic early Bronco body. "1966 above the chassis, 2026 below."

Thanks to everyone who hung out in the live chat!

🔧 Mooney Offroad: https://www.mooneyoffroad.com/

Hosts:

Jon Melton

Donnie Whiteman

Matt Mooney

Jon and Donnie are looking back over the year, talking about their favorite moments of 2024 and plans for 2025.

What is the "have to have" for you? Jon and Donnie drove around in Jon's truck and answered a bunch of "This or that" questions.

Watch the full video here: https://youtu.be/-fBE7IAp1ug

Are you in the market for a classic Early Ford Bronco? Before you buy, it’s crucial to know where these iconic 4x4s are most likely to have rust issues. In this video, we take a deep dive into all the common rust-prone areas of an Early Bronco, walking you through exactly what to look for when inspecting one. Whether you’re a seasoned collector or a first-time buyer, this video is packed with valuable tips to help you spot potential problem areas and avoid costly mistakes. Using a well-worn Bronco without an engine, transmission or interior as our example, we highlight the key areas where rust is typically found, including:

00:00 - Donnie bought a new Bronco

01:38 - Common Bronco hardtop rust areas

03:09 - Rust areas in engine bay and inner fenders

08:08 - Checking Door jambs, A-pillars, and B-pillars

09:48 - Early Bronco Floor pans and underbody

11:21 - Tailgate and rear quarter panels

15:08 - How much did Donnie pay for this Bronco?

From the top to the undercarriage, we provide a detailed walkthrough of how to identify hidden rust spots that could affect the structural integrity or resale value of your Early Bronco. Whether you’re restoring a classic or looking for a reliable trail rig, knowing these rust zones is critical to finding the right Bronco for your needs.

Jon tells us his favorite bronco pick from Donnie's SEMA video and we have two special guest interviews from SEMA 2024 to share!

FULL SEMA VIDEO HERE: https://www.youtube.com/watch?v=DY3ZJkE3wjo&t=247s

Electric Soft Top https://www.bestop.com/etop/?gad_source=1

Early Bronco Sway Bars https://tomsoffroad.com/parts/66-77-ford-bronco-3-5-5-inch-lift-front-anti-sway-bar/

Rear Dual Cup Holder https://amzn.to/3TqU0lC

Front Runner Roof Rack https://tomsoffroad.com/parts/ford-bronco-4-door-w-hard-top-2021-current-slimline-ii-roof-rack-kit-by-front-runner/

Under seat vent deflector https://amzn.to/3ZrZznE

ADS Suspension https://www.adsshocks.com/platform/ford/bronco/2021-2024/

Rear Seat Back cover https://amzn.to/3MOAgEw

Power Master Alternator (may not be the right model) https://amzn.to/41b4cTE

TOMS OFFROAD 10% off Site Wide https://tomsoffroad.com/

PSC Steering Kit https://tomsoffroad.com/parts/psc-x-toms-offroad-steering-gear-ram-assist/

Toms Big Brake Kit https://youtu.be/lef5dKtXDuE?si=mJiUklxS9tN_Al2J

QUESTION - Have a question about the show? Drop it in the comments or email us at Questions@theBronCast.com

Jon and Donnie talk through there Ford Bronco Restorations, where they are at, and what they have been working on.

"Why are the 2024 Ford Bronco Prices Coming Down? What are the interior package problems? Do people still not view Ford as a vehicle that lasts? Bronco still doesn't have a V8, but Jeep has a V8?"

What does wheeling look like in Alaska? What's your favorite tool on your 4200 mile trip? How many Bronco's have you had? Favorite upgrade you've done to your bronco? What's the craziest thing that happened on your trip from Alaska to Colorado?

We Talk To Chris Greenwood with Greenwood Racing! "What's the craziest thing that has happened in a desert race? What Mods can you do to the truck? How Do The Radius Arm Mounts Hold Up? What Is It About The Bronco That Made You Choose It?"

00:00 - Intro

04:42 - Driving Matt's Garage Early Bronco

06:15 - Tom's Offroad Rock and Roll Event

07:15 - Frame Horn repair Kit for the Early Bronco

09:38 - Track Bar Riser bracket for Dana 44

11:03 - Tubular Extended front radius arm Early Bronco

11:52 - Heavy duty Stock radius arm for Early Bronco

12.35 - New front bumper for early bronco

13:57 - replacement rear fuel tank brackets

14:25 - Ford 302 Oil Pan reinforcement rails

16:08 - Stainless Steel 23 gallon tank for Early Bronco

17:06 - 6R80 to Small Block Ford Adapter Plate

18:43 - Vented inner wheel well Early Bronco

19:24 - Early Bronco Hood prop stiffening braces

20:50 - Lower Grill Filler Panel

21:32 - Deluxe Center Console for Early Bronco

22:58 - Fender Liner for Early bronco

24:15 - Coil-over suspension kit for Early Bronco

25:46 - 4 link kit for Early Bronco

Frame Horn Repair Kit: https://tomsoffroad.com/parts/front-r...

Track Bar Riser bracket for Dana 44: https://tomsoffroad.com/parts/trackin...

Tubular Extended front radius arm: https://tomsoffroad.com/parts/tubular...

Heavy duty Stock radius arm: https://tomsoffroad.com/parts/heavy-d...

Impact Front bumper: https://tomsoffroad.com/parts/66-77-f...

Rear fuel tank brackets: https://tomsoffroad.com/parts/66-76-f...

Ford 302 Oil Pan reinforcement rails: https://tomsoffroad.com/parts/oil-pan...

Stainless Steel 23 gallon tank: https://tomsoffroad.com/parts/23-gall...

6R80 to Small Block Ford Adapter Plate: Coming Soon!

Vented inner wheel well: Coming Soon!

Hood prop stiffening braces: Coming Soon!

Lower Grill Filler Panel: Coming Soon!

Deluxe Center Console: Coming Soon!

Fender Liner: Coming Soon!

Coil-over suspension kit: Coming Soon!

4-Link kit for Early bronco: Coming Soon!

We interviewed and saw so many amazing Broncos at the Great Smoky Mountain Bronco Stampede. Check out some of our favorites!

Justin also arranges the Great Smoky Mountain Jeep invasion a week following this bronco show. They have over 20,000 jeeps at that show! Let’s beat that number next year for GSM!

Follow Jon and Donnie

Jon - https://www.instagram.com/nashvilleearlybronco/

Donnie - https://www.instagram.com/dreamweaverdonnie/

The BronCast YouTube: https://www.youtube.com/@TheBronCast

Toms Offroad: http://www.tomsoffroad.com/

QUESTION - Have a question about the show? Drop it in the comments or email us at Questions@theBronCast.com

At the Great Smoky Mountain Bronco Stampede, Donnie found this modified 2024 Bronco Raptor and took it for a drive!

Follow Jon and Donnie

Jon - https://www.instagram.com/nashvilleearlybronco/

Donnie - https://www.instagram.com/dreamweaverdonnie/

The BronCast YouTube: https://www.youtube.com/@TheBronCast

Toms Offroad: https://tomsoffroad.com/

QUESTION - Have a question about the show? Drop it in the comments or email us at Questions@theBronCast.com

The Blanco Bronco clan was at Toms Offroad Rock and Roll Event, and we caught up with Derek and he took us around his 60,000 mile 6th Gen Bronco, let me drive it, and we got to talk with his family.

Blanco Bronco YouTube: https://www.youtube.com/@blancobroncoadventures

Follow Jon and Donnie

Jon - https://www.instagram.com/nashvilleearlybronco/

Donnie - https://www.instagram.com/dreamweaverdonnie/

The BronCast YouTube: https://www.youtube.com/@TheBronCast

QUESTION - Have a question about the show? Drop it in the comments or email us at Questions@theBronCast.com

This Bronco is a beast! 40” tires, 408 stroker, and a 6 speed transmission! Lets see if he’ll let me drive it

Follow Jon and Donnie

Jon - https://www.instagram.com/nashvilleearlybronco/

Donnie - https://www.instagram.com/dreamweaverdonnie/

The BronCast YouTube: https://www.youtube.com/@TheBronCast

QUESTION - Have a question about the show? Drop it in the comments or email us at Questions@theBronCast.com

We are at Tom's Rock and Roll event in Medford, Oregon. Follow along as we check out some of the Ford Bronco's we got to drive!

Matt's Garage YouTube channel:

https://www.youtube.com/@MattsGarage

Toms Offroad: http://www.tomsoffroad.com/

Follow Jon and Donnie

Jon - https://www.instagram.com/nashvilleearlybronco/

Donnie - https://www.instagram.com/dreamweaverdonnie/

The BronCast YouTube: https://www.youtube.com/@TheBronCast

QUESTION - Have a question about the show? Drop it in the comments or email us at Questions@theBronCast.com

This Ranger Bronco was on the podcast a few months ago when we talked about how the Ranger package was unique. In this episode, Jon and Donnie take the Ranger for a drive, but the Ranger doesn't want to run right.

Steering linkage with new ball joints - https://tomsoffroad.com/parts/76-77-ford-bronco-inverted-y-steering-linkage

Front suspension C bushings and Radius arm bushings - https://tomsoffroad.com/parts/66-75-ford-bronco-4-degree-front-suspension-bushings

Front Disc Brake Conversion - https://tomsoffroad.com/parts/66-75-ford-bronco-complete-front-disc-brake-conversion

Parking brakes - https://tomsoffroad.com/parts/66-76-ford-bronco-parking-emergency-brake-levers

Jon and Donnie walk around Donnies $68,000 early Ford Bronco restoration. Donnie shared his budget with us a few episodes back, now we get to take a look at what he's been working on.

00:00 - Welcome

01:00 - Exterior Overview

01:50 - Under The Hood

05:40 - Interior Overview

In this episode, Jon and Donnie discuss early Bronco steering geometry with practical tips and key insights.

• Excessive Movement in the Engine bay - With the tires on the ground, saw the steering wheel back and forth looking for excessive movement or play in the engine bay. Steering box, steering shaft.

• Excessive Movement under the Bronco - With the tires on the ground, saw the steering wheel back and forth looking for excessive movement or play. If you have a steering stabilizer, remove it for a more accurate check. Check from the passenger side to the driver side:

•

• Ball Joints
• Trac Bar
• Tie Rod ends
• Drag link
• Pitman arm
• Ball joints

• Trac Bar play - On the ground, remove Trac Bar and show what happens when the Trac Bar bolt breaks free, or when the Trac Bar bushing goes bad. Saw the steering back and forth and watch the body move side to side over the axle.

• New mounting bolts - https://tomsoffroad.com/parts/66-75-ford-bronco-grade-8-track-bar-mounting-bolts

• Tie Rod and Drag Link parallel - With the Bronco in the air, talk about why it’s important to have the Tie Rod and Drag Link parallel. How to get them closer -

• Drop Pitman arm - https://tomsoffroad.com/parts/66-76-77-ford-bronco-drop-pitman-arm
• Trac Bar drop bracket - https://tomsoffroad.com/parts/66-75-ford-bronco-track-bar-drop-bracket
• Trac Bar Riser
• Tie Rod Over vs. Under

• Caster Angle - Talk through why Caster angle is important, have an alignment shop test your caster and give you the angle. Jon show his alignment sheet. How to fix caster:

• C Bushing 2 degrees - https://tomsoffroad.com/parts/66-75-ford-bronco-2-degree-front-suspension-bushings
• C Bushing 4 degrees - https://tomsoffroad.com/parts/66-75-ford-bronco-4-degree-front-suspension-bushings
• C Bushing 7 degrees - https://tomsoffroad.com/parts/66-75-ford-bronco-7-degree-front-suspension-bushings
• Tow in 3 degrees, ¼”

• U-Bolts - Believe it or not, loose U-bolts in the back of your Bronco can cause steering problems on a Bronco. Tighten Ubolts to 60-100 ftlbs (don’t overtighten or you will egg shape the axle tube).
• Spindle Lock nuts -

• New spindle lock nuts - https://tomsoffroad.com/parts/66-77-ford-bronco-dana-30-44-spindle-nut-kit

• Tire Pressure - How to check tire pressure with chalk

Follow Jon and Donnie Jon - https://www.instagram.com/nashvilleearlybronco/ Donnie - https://www.instagram.com/dreamweaverdonnie/ QUESTION - Have a question about the show?

Drop it in the comments or email us at Questions@theBronCast.com

Today we're talking about the things I wish I knew before starting a bronco restoration, and also sharing what we spent on our Ford Bronco Restorations!

Questions@thebroncast.com