BDS Bronco Pickup Truck

Missed the earlier episodes? Click here to check out Episode 1  |  Episode 2  |  Episode 3

In just 10 weeks, BDS, makers of extreme duty suspension, have completely overhauled a bone stock 2 door Ford Bronco Black Diamond Edition into a mission-ready "half-cab" Bronco pickup. Built with a backwoods fire/rescue theme, the ultra-capable Bronco is designed to help a fire chief or command-lead get on-site quickly. The goal is to assess each situation and build a tactical plan of attack for the team. "Fire Command" as it's been dubbed, is a one-of-a-kind short wheelbase Bronco truck that pays homage to the early Broncos used by many rural fire departments decades ago.

Equipped with the right gear to get the job done, Fire Command is ready for action thanks to suspension upgrades with oversized wheels and tires, dual winches, state-of-the-art comms, emergency lighting, first aid, an assortment of tools, storage, and much much more. Given BDS's reputation and background, it's no surprise this Bronco is outfitted with the latest and greatest BDS and FOX components. Along with the half cab conversion, the "bed" has been fitted with a custom bottom-hinged drop tailgate in place of the swing gate that gains access to a slide-out storage tray. If you missed how Project Fire Command took shape, be sure to check back through the entire build series to see how this Bronco came to be.

Watch Build Episode 1
Intro, Teardown & Fabrication

Watch Build Episode 2
Suspension, Wheels & Tires

Watch Build Episode 3
Bumpers, Lights & Much More

Vehicle:

Ford Bronco 2Dr (Black Diamond Edition)
2.3L Engine | 7-speed manual transmission
Race Red Paint Color

Build Specs:

Performance:
Hypertech React Offroad + Speedo Calibrator (more info)
Ford Performance by Borla Catback Exhaust System

Suspension:
BDS 4” DSC Coilover Lift System (more info)
- FOX 2.5 Performance Elite Series Coilovers w/ DSC
- BDS Uniball Upper Control Arms
BDS Adjustable Rear Upper/Lower Control Arms & Track Bar

Wheels & Tires:
37x12.50x17 Nitto Trail Grapplers (more info)
17x9 Method Series 106 Beadlocks (custom powdercoat) (more info)

Exterior:
Half Top Conversion (modified OE MIC hard top) – painted race red
Lower Half Top Bulkhead
Drop Tailgate Conversion
Crawltek Modular Front Winch Bumper (more info)
Crawltek Rear Winch Bumper (more info)
Dual (Front+Rear) Warn VR Evo 10-S Winches w/ Epic Hooks (more info)
Crawltek Fender Trim Kit (more info)
Fabricated Tonneau Cover
Yakima LoadWarrior basket w/ misc accessory mounts (more info)
ARB Jack w/ custom mounts (more info)
Axe, Shovel, Chainsaw, First Aid, PPE, Emergency Comms
RCV 300M Axle Shafts

Lighting:
Rigid 360-series 6” LED lighting (red backlit) for roof (more info)
Rigid 360-series 4” LED lights on cowl (more info)
Rigid SR-M LED Lights on bed rack (more info)
Rigid A-Series LED underbody lights (more info)
LED Emergency Flashers

Interior:
Katzkin Leather Seats (black & red w/ embroidery) (more info)
Ford OE Upfitter Switches to control lighting
Rescue Siren/PA System
Garmin Overlander GPS Unit and Camera (more info)
Fabricated rollcage to tie into factory rollbar
Ford Performance Door Sill Plates
Ford Performance Floor Mats (more info)
Ford Performance Fire Extinguisher
CargoGlide Trailslide Tray System (more info)
Ford Performance by Warn Recovery Kit (more info)

Thanks again to all our build partners for their support - Ford, FOX, Crawltek, Nitto, Method, RCV, Warn, Rigid, ARB, Katzkin, Yakima, CargoGlide, Hypertech, Garmin and more. #ProjectFireCommand

Missed the earlier episodes? Click here to check out Episode 1 or Episode 2

With the deadline of SEMA looming, the build team is starting to feel that all too familiar SEMA crunch as the kick it into high gear to get this build buttoned up and hit the road for Vegas. After weeks of design, development, fabrication, paint and more, parts have gone one and off this build in preparation for final install. On the docket this week, wiring up lights, winches and other accessories, bolting on winch bumpers, finish closing out the cab, installed the rack and add all the accessories to transform this Bronco into the fire/rescue themed Bronco 2Dr truck it was destined to be.

The team at Crawltek Revolution (sister company of BDS) came in to design a set of one-off prototype winch bumpers for front and back. These bumpers maximize approach and departure angles, add strength, add recovery points and just flat out look amazing on this build. Mounted behind them are a pair of Warn VR Evo 10-S winches for recovery duties from either end of the vehicle. For lighting this Bronco is getting an assortment from the lighting pros at Rigid with 360-series red backlit lights on windshield, SR-M series on the rear and rack, and A-series underneath.

To go along with the custom half-top, the build team showed off their skills fabbing up a lower bulkhead to enclose the cab, built a rear bed enclosure, added a custom tonneau cover for dry storage and (to me) the coolest feature, built a custom drop tailgate to allow access to the CargoGlide rear slide out tray to hold all the gear needed. Up top, a Yakima Load Warrior basket was mounted to the tonneau cover for allowing room for more gear and like the fire extinguisher, ARB jack, chainsaw, axe, shovel and more. Around the outside of the rack are more Rigid lights and LED emergency flashers. These flashers can be found all around the vehicle as part of the emergency package that adds a siren and PA system to alert others to move out of the way of this Bronco. All switches are run through the 6 factory upfitter switches for a clean appearance inside the cab. Also inside, the stock seats are getting upgraded with Katzkin 2-tone leather with embroidered headrests. A Garmin Overlander offroad GPS adds to the factory nav screen to help navigate to and from each mission. Under the hood the stock 2.3L gets a more throttle response from a Hypertech module along with some meatier notes compliments of the Ford Performance cat-back exhaust system.

Stay tuned as the team buttons up this custom Bronco just in time for SEMA. The reveal goes live at 10am EST Tuesday of SEMA so be on the lookout for that! Thanks again to all our build partners in Ford, FOX, Crawltek, Ford Performance, Nitto, Method, RCV, Warn, Rigid, ARB, Katzkin, Yakima, CargoGlide and more.

#ProjectFireCommand

FOX Performance Elite Coilovers

Missed Episode 1? Check it out Here

Missed Episode 1? Check it out Here

We're back with the 2nd installment of the BDS SEMA Bronco build. BDS installs its all-new Bronco coilover suspension system with FOX Performance Elite Series shocks and BDS extreme duty control arms. It's a key goal in transforming a regular old run-of-the-mill 2.3L manual Ford Bronco 2-door into an awe-inspiring Fire/Rescue-themed truck. Following the progress made in Episode 1, the BDS build team dives deep into the conversion as they begin putting the Bronco back together. Components are being fabricated, parts are coming in from build partners and things are starting to take shape. Project Fire Command will no doubt be a truly unique short wheelbase Bronco.

With the idea this Bronco could be used by the fire chief or command lead on their way to rescue missions, this Bronco needs to to be capable of let's call it "spirited" driving on and offroad. With that in mind we turned to our friends at FOX for their soon to be released latest and greatest for new Bronco, the 2.5 Performance Elite Series coilovers with remote DSC adjustment. Now these coilover build on the race winning technology that FOX builds into each and every shock. These new Performance Elite Series feature an aluminum body for more rapid heat dispersion offroad, massive 7/8” hardened chrome shafts, dual speed compression (DSC) adjustment and are dialed for this Bronco. The shocks are paired with the recently released BDS performance series uniball upper control arms to take advantage of the additional travel making this an unbeatable combination for comfort and capability. These BDS 3.5-4.5" (2Dr) and 3-4" (4Dr) DSC coilover systems will begin shipping December 2021, see more here.

Along with the 4-corner FOX coilovers and front BDS upper control arms, this Bronco is featuring a number of pre-production upgrades to include rear HD adjustable upper and lower control arm and an adjustable rear track bar. For wheel and tires this truck needs a rugged setup that won't let us down no matter how extreme the terrain so we opted for the tired and true King of the Hammers conquering 37x12.50x17 Nitto Trail Grappler tires mounted on 17x9 Method Series 106 beadlock wheels finished in a custom gold/black powder coat to really set them off for this build. These things look killer

With that its back to work, we still a long way to go and a short time to get there. SEMA is right around the corner. A big thanks to our build team for their continued hard work and the build partners in Ford, FOX, Crawltek, Ford Performance, Nitto, Method, RCV, Warn, Rigid, Katzkin, Yakima, CargoGlide, and more. Stay tuned for the updates to come as the BDS team outfits this Bronco into Project Fire Command.

#ProjectFireCommand

Well its that time of year again... SEMA is right around the corner and we're kicking off the latest project build, a 2021 Ford Bronco 2Dr to debut in Ford's booth at Central Hall of the show. Anybody that has followed BDS for a few years may recognize a pattern and you'd be right, we're teaming up with Ford Motor Company on another build through their Project Vehicle program. This year marks the 5th consecutive project vehicle we've taken on. In the past this included SD126 in 2017, followed by RangerX in 2018, then Go Beyond in 2019 and Work/Play for the virtual SEMA of 2020. If you haven't checked out those custom project builds use the links below to check out each of the full build threads complete with photos, videos, write ups, action content and more.

Project SD126
#projectSD126

Project RangerX
#projectRangerX

Project GoBeyond
#projectGoBeyond

Work/Play F150
#workplayF150

So what do we have planned for this latest build?! A fire-rescue themed short wheelbase Bronco truck built to ultra capability able to lead the charge as the Fire Command setting up the tactical recovery, rescue, or whatever the mission may be. This off-road ready Bronco took inspiration the multitude of early Broncos that have found there way into rural fire departments for similar duties. This build is coming together down in the BDS R&D shop over the course of about 8 weeks for the team to design, fabricate and ultimate outfit this Bronco with the right gear to get the job done.

Starting with a Black Diamond edition 2021 Ford Bronco 2Dr in race red, the team went to work tearing into the factory fresh Bronco pulling out the hard top, the bumpers, suspension, seats and interior panels. From there measurements were taken, vehicle CAD was obtained and the first of many cuts were made lob off the back half of the roll bar, followed shortly after by the MIC hardtop getting chopped into pieces, all with the intention of building a one-off 1/2-cab Bronco truck reminiscent of the original Bronco 1/2-cab hardtop option. With top cut up and the structure built our with reinforcements, the top made its way over to the pros at Butler Body Shop to take on the body work to fill, shape and finish the top to look as though it rolled off the assembly line with the factory option. While we don't expect to be the only ones wanting to see Ford offer a Bronco truck in the market, we're not holding out breathe for it happening anytime soon. Stay tuned for progress on the top.

Beyond tear down and the mayhem of body mods, the team is ordering the rest of the parts to outfit this Bronco and get it ready for action. This Bronco will sport a number of prototype components from FOX, BDS, Crawltek and Ford Performance. It'll also have its fair share of fabricated parts along with other upgrades from many of the go-to aftermarket companies like Nitto, Method, RCV, Warn, Rigid, Katzkin, Yakima, CargoGlide, and more. Stay tuned for the updates to come as the BDS team outfits this Bronco into Project Fire Command.

#ProjectFireCommand

Continue on to Episode 2

PR421-1
BDS ups the ante with new 3.5" DSC Coilover Systems for the 2019-2020 Ford Ranger. These systems build on the current 3.5" (2.0) coilover option with the new FOX 2.5 Performance Elite Series DSC coilovers and shocks for next level level offroad performance, capability and tunable ride quality. These new 3.5” coilover systems are deisgned to utilize the factory suspension mounting points to offer improved ground clearance and wheel travel with room for 33-34" tires. In the rear your choice of FOX 2.0 IFP or 2.5 DSC shocks. As with all BDS lift kits, these new kits are backed by Factory Protection Plus for piece of mind wherever your adventures may take you. Factory Protection Plus includes BDS’s exclusive No Fine Print Warranty, ESC system compatibility and a 5-year 60,000-mile drivetrain warranty.

Product Description

3.5" DSC Coilover System

Install Time/Difficulty

4 Hours / 3 of 5

Rec'd Wheel/Tire Specs

275/65r20 Tires on 20x9 Wheels (6.18" BS)
285/60r18 Tires on 18x9 Wheels (5.5-5.75" BS)
305/55r20 Tires on 20x9 Wheels (5" BS)

Factory Protection Plus
  • 5-year, 60,000 mile drivetrain Warranty
  • BDS’s exclusive No Fine Print Warranty

***Check the BDS website to verify details prior to ordering to ensure information is up-to-date with current manufacturer listings***

Product Info

1545FDSC - 3.5" DSC Coilover System w/ FOX 2.0 IFP Rear Shocks

1587FDSC - 3.5" DSC Coilover System w/ FOX 2.5 DSC Rear Shocks

Features/Benefits

  • FOX 2.5 performance elite series DSC remote reservoir coilovers for next level performance on any terrain and easy adjustment.
  • Performance UCAs add strength and increase droop travel.
  • Increased ride height and levels front/rear stance with room for 33-34” tires.
  • All components come ready to install right out of the box, no setup or tuning needed.
  • Differential relocation to correct CV operating angle.
  • Front fender intrusion beams to optimize clearance for larger tires.
  • Rear HD shackle kit improves travel and levels stance.
  • Available with either rear FOX 2.0 performance series IFP or FOX 2.5 performance elite series piggyback DSC shocks to match the front performance.

Coldwater, MI: BDS Suspension raises the bar with new 3.5” DSC Coilover Lift Systems designed to take advantage of the stout factory front suspension design on the 2019-2020 Ford Ranger. At the heart of these 3.5" DSC coilover systems are a pair with the new aluminum-bodied FOX 2.5 performance elite series coilovers. These coilovers are preset for the correct lift height right out of the box and use a threaded body to allow preload adjustment. They are a direct bolt-in replacement for the factory strut assemblies and improve damper performance featuring a 2.5" extruded and machined 6061 T6 aluminum body for better heat dispersion, along with 7/8" hardened steel carbon shaft, Eibach coil springs and black anodized machined 6061-T6 billet aluminum mounts along with remote reservoirs with mounting brackets. The DSC (dual speed compression) reservoir allows for easy tool-free adjustment of high-speed and low-speed compression adjustment settings to further dial in the damping to the terrain and ride preferences. Also supplied for the front end are a pair of performance upper control arms (UCAs) designed for improved strength and suspension travel. Built from thick wall 1.5” DOM tubing, these UCAs utilize an indexed ball joint cup to reposition the upper ball joints and allowing more droop travel. These arms come fully assembled right out of the box with high quality greaseable ball joints and rubber bushings for long life, quiet operation and superior corrosion resistance over uniballs and heims. Finishing out the front of these 3.5” systems are fully fabricated differential relocation brackets to correct CV axle operating angles.

In the rear of these lift systems the factory leaf springs are retained and 1” lift comes from a heavy duty replacement shackle. These shackles are built from high strength 3/8” steel and have the benefit of leveling the stance, correcting rear pinion angle and allowing for increased rear suspension travel. Also supplied for the rear of these 3.5” lift kits are a pair. Also supplied for the rear of these 3.5” lift kits are your choice of FOX 2.0 performance series IFP shocks or upgraded FOX 2.5 factory series DSC adjustable shocks to match the front performance and adjustability. These kits come finished in a durable black powdercoat finish and sent with all hardware packs to complete the install along with step-by-step installation instructions.

All BDS kits include Factory Protection Plus for the ultimate extended warranty to include BDS’s No Fine Print Warranty, ESC System compatibility and a 5year-60,000mile drivetrain warranty to match the dealer. Improve the look and capability of your 2019-2020 Ford Ranger with these new 3.5” coilover lift systems from BDS Suspension.

Media Gallery

3.5" DSC C/O Kit (Rear 2.0s)

#1545FDSC

 

3.5" DSC C/O Kit (Rear 2.5s)

#1587FDSC

 

3.5" DSC C/O Kit (Rear 2.5s)

#1587FDSC

 

© BDS Suspension, 491 W. Garfield Ave. Coldwater, MI 49036
(517) 279-2135 | bds-suspension.com | sales-bds@ridefox.com

PR407-1

BDS Suspension adds next level performance to its lineup RAM 1500 lineup with 2" coilover systems for the 2013-2018 RAM 1500 trucks. These new 2" performance leveling systems improve all around vehicle performance and capability with your choice of FOX 2.0 performance series IFP coilover or FOX 2.5 factory race series remote reservoir coilovers with DSC adjustment for next level ride and damper capability. Additionally these kits utilize BDS performance series upper control arms and FOX 2.0 performance series IFP rear shocks alowing clearance for up to 33" tires. As with all BDS lift kits these new 2" system includes Factory Protection Plus for the ultimate extended warranty. Factory Protection Plus includes BDS’s No Fine Print Warranty and a 5year-100,000mile drivetrain warranty to match the dealer. Take your RAM 1500 to the next level with BDS Suspension and FOX.

Product Description

2” Coilover Leveling Kits
for 2013-2018 RAM 1500 4WD

Product Info

BDS1665FSL – 2” Coilover Leveling Kit
(2.0 Performance Series IFP Coilovers & Shocks)

BDS1665FDSC – 2” Coilover Leveling Kit
(2.5 Factory Race Series DSC R/R Coilovers & 2.0 Performance Series IFP Rear Shocks)

BDS1696FDSC – 2” Coilover Leveling Kit
(2.5 Factory Race Series DSC R/R Coilovers & 2.5 Factory Series DSC R/R Rear Shocks)

Vehicle Fitment

2013- 2018 RAM 1500 4WD
*non air-ride

Features/Benefits:

  • FOX 2.5 factory series remote reservoir coilovers for next level performance on any terrain.
  • Coilovers feature DSC adjusters to dial in high speed and low-speed compression settings
  • Performance UCAs add strength and increase suspension travel
  • Increased right height and levels front/rear stance with clearance for 33" tires
  • Rear FOX 2.0 IFP or 2.5 piggyback shocks for improved performance

Rec'd Wheel/Tire Specs

33x12.50 Tires on 20x9 Wheels (5" BS)
33x12.50 Tires on 18x9 Wheels (5" BS)

Factory Protection Plus
  • 5-year, 100,000 mile drivetrain warranty
  • BDS’s exclusive No Fine Print Warranty

***Check the BDS website to verify details prior to ordering to ensure information is up-to-date with current manufacturer listings***

(1665FSL) These 2" Coilover Systems are designed to build on the stout factory front suspension design on the RAM 1500 trucks and take performance to the next level while leveling out the stance. At the heart of these 2" leveling kit are a pair of specially tuned FOX 2.0 performance race series coilovers. These non-reservoir coilovers are preset for the correct lift height right out of the box and use a threaded body to allow preload adjustment. They are a direct bolt-in replacement for the factory strut assemblies and improve damper performance featuring a 2.0" extruded and machined 6061 T6 aluminum body for better heat dispersion, along with an internal floating piston (IFP) to eliminate oil aeration, FOX’s proprietary internals, 5/8" hard chrome plated heat treated alloy shaft all preloaded with coil springs ready for easy installation.This kit takes performance for the next level by upgrading to FOX 2.0 performance series. Also supplied for the front end are a pair of performance upper control arms (UCAs) designed for improved strength and suspension travel. Built from thick wall 1.5" DOM tubing, these UCAs utilize an indexed ball joint cup to reposition the upper ball joints and allowing more droop travel. These arms come fully assembled right out of the box with high quality greaseable ball joints and rubber bushings for long life, quiet operation and superior corrosion resistance over uniballs and heims.

In the rear of these lift systems the factory coil springs are retained to result in a level stance in no change in tow/load capacity. A pair of FOX 2.0 performance series IFP shocks are supplied to match the front performance.

(1665FDSC/1696FDSC) These 2" Coilover Systems are designed to build on the stout factory front suspension design on the RAM 1500 trucks and take performance to the next level while leveling out the stance. At the heart of these 2" leveling kit are a pair of specially tuned FOX 2.5 factory race series coilovers available with DSC (dual speed compression) adjusters. These coilovers are backed by FOX's racing pedigree, preset for the correct lift height right out of the box to provide optimal performance and direct bolt-in replacement for the factory strut assemblies. They feature a smooth bore and honed seamless alloy body, 7/8" hardened steel carbon shaft, Eibach coil springs and black anodized machined 6061-T6 billet aluminum mounts along with remove reservoirs with mounting brackets. The DSC reservoir allows for easy tool-free adjustment of high-speed and low-speed compression adjustment settings to further dial in the damping to the terrain and ride preferences. Also supplied for the front end are a pair of BDS performance upper control arms (UCAs) designed for improved strength and suspension travel. Built from thick wall 1.5" DOM tubing, these UCAs utilize an indexed ball joint cup to reposition the upper ball joints and allowing more droop travel. These arms come fully assembled right out of the box with high quality greaseable ball joints and rubber bushings for long life, quiet operation and superior corrosion resistance over uniballs and heims.

In the rear of these lift systems the factory coil springs are retained to result in a level stance in no change in tow/load capacity. A pair of FOX 2.0 performance series IFP shocks (1665FDSC) or upgraded FOX 2.5 factory series DSC remote reservoir shocks (1696FDSC) are supplied to match the front performance.

All BDS kits include Factory Protection Plus for the ultimate extended warranty to include BDS’s No Fine Print Warranty, ESC System compatibility and a 5year-100,000 mile drivetrain warranty to match the dealer. Improve the look and capability of your RAM 1500 truck with these new 2" coilover leveling systems from BDS Suspension.

Media Gallery

© BDS Suspension, 491 W. Garfield Ave. Coldwater, MI 49036
(517) 279-2135 | bds-suspension.com | sales-bds@ridefox.com