DESIGN PHILOSOPHY
Chassis Design Philosophy
The chassis was designed around two primary goals: preserving the iconic appearance of the classic Bronco while maximizing performance, durability, and serviceability.
By starting with a completely custom chassis, every component could be positioned exactly where it needed to be. Suspension mounting points, drivetrain packaging, storage solutions, and safety systems were all engineered from the ground up rather than being constrained by factory frame geometry.
Throughout the build, significant effort was made to preserve the classic Bronco appearance. The original fender profiles, grille, headlights, taillights, windshield angle, and windshield taper remain instantly recognizable while concealing a modern purpose-built off-road chassis underneath.
The result is a vehicle that maintains the timeless look of the original Bronco while delivering modern performance, capability, and reliability.
CHASSIS STRUCTURE
.120 WALL DOM CONSTRUCTION
.120 Wall DOM Construction
The entire chassis and roll cage structure are constructed from .120 wall DOM tubing.
DOM tubing was selected for its superior strength, consistency, and durability while maintaining a reasonable overall vehicle weight.
Benefits include:
- Exceptional structural strength
- Improved impact resistance
- Increased durability
- Integrated occupant protection
The chassis serves as both the vehicle structure and roll cage system.
WINDSHIELD FRAME DESIGN
CLASSIC APPEARANCE, MODERN STRENGTH
Classic Appearance, Modern Strength
The windshield frame is constructed from square tubing to maintain the distinctive appearance of the factory Bronco windshield frame.
Unlike many custom tube chassis vehicles, the windshield retains the flat-sided profile of the original Bronco while functioning as a structural component of the roll cage.
This design preserves the classic appearance without sacrificing strength.
SUSPENSION INTEGRATION
PURPOSE-BUILT SUSPENSION MOUNTING
Purpose-Built Suspension Mounting
One of the greatest advantages of building a chassis from scratch is the ability to position suspension mounting points exactly where they are needed.
Rather than adapting the suspension to fit a factory frame, the frame was designed around the suspension.
Benefits include:
- Optimized anti-squat geometry
- Optimized anti-dive geometry
- Improved climbing performance
- Enhanced stability
- Greater suspension tuning flexibility
This approach allows the suspension to perform exactly as intended.
INTEGRATED LOWER LINK MOUNTS
Integrated Link Mount Design
Special attention was given to protecting suspension components from trail damage.
The frame sections where the lower links attach utilize 3x4 rectangular tubing, allowing the mounts to be integrated into the chassis rather than hanging below it.
Benefits include:
- Increased ground clearance
- Reduced rock hang-ups
- Improved durability
- Better obstacle clearance
This seemingly small detail has a significant impact when navigating difficult terrain.
CHASSIS BODY ARMOR
3/16-Inch Steel Rear Fenders
The rear fenders are custom fabricated from 3/16-inch steel plate.
These components were designed to serve multiple purposes beyond simply functioning as body panels.
Benefits include:
- Body protection
- Structural reinforcement
- Impact resistance
- Trail durability
Rather than functioning solely as body panels, they contribute directly to the overall strength and durability of the chassis.
ROCK PROTECTION
HEAVY-DUTY ROCK SLIDERS
Heavy-Duty Rock Sliders
The rock sliders are built from 2-inch DOM tubing with a 1/4-inch wall thickness.
Designed to support the full weight of the vehicle, they provide critical protection when sliding across rocks and obstacles.
Benefits include:
- Chassis protection
- Body protection
- Improved obstacle navigation
- Increased durability
These components are intended to be used, not simply installed.
INTEGRATED SERVICE ACCESS
DASHBOARD ACCESS PANELS
Integrated Service Access Panels
Two hinged access panels are built directly into the dashboard.
These panels provide convenient access to:
- Fuse panels
- Relays
- Engine management systems
- Vehicle electronics
This eliminates the need to crawl underneath the dashboard for routine maintenance and troubleshooting.
ALUMINUM INTERIOR COMPONENTS
FLOOR PANS & TUNNEL COVERS
Aluminum Floor Pans & Tunnel Covers
All floor pans and tunnel covers are fabricated from aluminum and finished with Rhino Lining.
Benefits include:
- Reduced weight
- Corrosion resistance
- Easy maintenance
- Increased durability
The Rhino Lining finish provides additional protection while creating a clean, functional interior.
STORAGE SOLUTIONS
RECESSED REAR TOOLBOX
Integrated Rear Toolbox
The rear toolbox is fabricated from aluminum and recessed directly into the chassis structure.
By locating storage lower in the vehicle, weight is kept closer to the ground, helping maintain vehicle stability while maximizing usable storage space.
Benefits include:
- Lower center of gravity
- Increased storage capacity
- Weight reduction
- Improved organization
This design provides practical storage without compromising vehicle performance.
FUEL TANK / RADIATOR COMPARTMENT
Integrated Systems Compartment
A custom enclosure located behind the seats houses several major vehicle systems in a single dedicated compartment.
Contained within this compartment are:
- Fuel tank
- Radiator
- Auxiliary electric water pump
- Vent canisters
This arrangement provides several advantages:
- Cleaner appearance
- Improved packaging
- Better weight distribution
- Simplified maintenance
Consolidating these systems into a dedicated compartment helps keep the vehicle organized, serviceable, and optimized for performance.
CUSTOM ALUMINUM ROOF PANEL
Custom Aluminum Roof Panel
The roof panel is formed from 1/8-inch aluminum, providing a lightweight and durable solution that complements the overall chassis design.
Benefits include:
- Reduced weight
- Corrosion resistance
- Structural rigidity
The roof also incorporates the BrockoJo logo, creating a unique visual signature that helps distinguish the build while reinforcing its custom identity.
SAFETY FEATURES
INTEGRATED FRONT STINGER
Integrated Front Stinger
A front stinger is built directly into the front bumper structure.
While it contributes to the aggressive appearance of the vehicle, its primary purpose is protection. It helps protect the hood and fenders during a rollover.
SEATING & OCCUPANT COMFORT
PRP SUSPENSION SEATS
PRP Suspension Seats
The interior features premium PRP suspension seats designed to provide both comfort and performance during extended trail rides and demanding off-road conditions.
Features include:
- Integrated seat heaters
- Adjustable lumbar support
- Front storage bags
- Long-distance comfort
- PRP racing harness
These seats help reduce driver fatigue while providing the support and comfort needed for both technical crawling and extended adventures.
Classic Bronco Inspired Dashboard
The dashboard was designed to resemble the original Bronco dash while incorporating modern functionality.
Maintaining the classic appearance was important, but serviceability was equally important.