DIY - Bronco Hoist on 10 foot sliding Track. ~ $150 build

djp

Jun 06, 2023

Hey all, it's Dan from BroncoBikini.com (100-MPH, Waterproof, Canvas Bimini's with video proof!)
It's getting hot out there, y'all take your tops off the easy way!

Want to raise your hard top, and slide it out of the way?
And want to do it without breaking the bank and in only 2 minutes?

Pricing Update: March 14, 2024. I just clicked the links and added pricing it's $124.

Then add the lag screws you need ~ $10. And if you dont have a metal step bit to drill the trolley hold a bit bigger that's another $10. So still under $150, pre tax.

Here is how....

[$36] 10' Unistrut - this is your track
- Link: Unistrut from Lowes
  - Even if you dont have room for a 10' track, get the 3' track. That way you dont have to perfectly back up, it will give you 3-feet of wiggle room
  - Take your trolley with you to lowes and run it in the track with some downward force. I noticed that one i grabbed the trolley got hung up on the track as it had some flaws. So pick a straight smooth one.
[$13] Strut Trolley - This trolley is mandatory, it has smaller wheels, if you plan on using lag bolts into studs through the Unistrut, you MUST get this trolley with the smaller wheels to bypass the bolt-heads. They claim it has 250-lb load rating.
- Link: Trolley on Ebay
[$59] Chain hoist - i like this 1/4 inch one as it has a non-greased chain and is clean and simple
- Link: Amazon Hoist
[$15] 2" Tree Swing straps - (8-foot -- but I tied knot in mine so they are about 7' now)
- Link: Amazon straps
(optional) Also get yourself a little bucket or bag, this will serve as your chain catch bucket/bag, so the excess chain doesnt droop down and rest on your hardtop.
Then some wood lag bolts and washers, make sure to lag screw into your studs
- My ceiling joists are 16" on center, so I have (7) total 3/16" x 1-3/4 lag screws into my studs/joists holding this up very strong!
END STOP
- Drill through the each end of your strut and put a bolt through it with a locking nut.
- This will keep your trolley (and possibly top) from flying off the end and shattering :)

Feel free to reach out to me on BroncoBikini.com if you have any questions or want pointers.
-Dan

That "red bucket thing" is a chain bag. I stole his sand castle bucket from the beach :).
I use it as a chain catch, so the lifting chain never touches my bronco top :)

I drilled a hole using a step bit into my trolley so i can make sure my hoist is as high as possible.
(Also note the "stop bolt" I have at the end of the track, so my top doesnt go flying off the track !!)
I'm also using the red bucket as a "chain catch" so it doesnt droop on the top of my hard top.

The bottom of the top is about 46" from the ceiling.
(measuring from ceiling drywall to bottom of hanging top)

Chief Ron, Pygmy Warrior

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Jun 07, 2023

Very cool…. I gotta ask, what’s the sand castle bucket (red) for?

Riding OB1, 23 4- door Outer Banks, SAS, MOD, MIC, Lux, Ordered 10/20/22, delivered 1/13/23

the poacher

Jun 07, 2023

djp
Want to raise your hard top, and slide it out of the way?

Here is how....

10' Unistrut - this is your track

Link: Unistrut from Lowes

Even if you dont have room for a 10' track, get a 3' track. That way you dont have to perfectly back up, it will give you 3-feet of wiggle room :)

Strut Trolley - get this one on ebay as it has smaller wheels that will bypass the lag-screws you use to anchor in the strut

Link: Trolley on Ebay

Chain hoist - i like this 1/4 inch one as it has a non-greased chain and is clean and simple

Link: Amazon Hoist

2" Tree Swing straps - You want 2" so it's wide and doesnt indent your weather seals, also the multi loop version makes it adjustable

Link: Amazon straps

Then some wood lag screws and washers

Some sort of bolt to drill through the end of the strut, as a stopper so they trolley doesnt fly off :)

And voila ! Video below !!
Also if you want, toss your middle section on it too !!
(unfortunately, I cut my straps to size for just the top, so when i added the middle section i had to add some webbing... and thus the reason I now suggest the tree straps with the pre-sewn loops so you can adjust it)

Video: Under 2-minute install

very nice. Though I fear the future photos from someone who doesn't think to anchor into studs.

Supreme Leader of the Wandering but NOT Lost
2022 OBX Cyber Orange Metallic with random acutriments.

Bluestreak57

Jun 07, 2023

Bluestreak57
Very cool…. I gotta ask, what’s the sand castle bucket (red) for?

That is my chain catch bucket.... It catches the chain loop that droops down (the excess chain when you raise the hoist)
I did not want the chain resting on my hard top, so I stole a bucket from my 6-yo :)

You usually see these chain catch bags on the more large scale industrial hoists
Really not necessary on the hoist that I suggest as the chain is very very clean and not the greasy type. Also I do not think any damage or scratches would happen with the chain to the top...but i had a bucket laying around so I used it.
Any sort of wide mouth canvas bag or bucket would work if you wanted this option, but again totally optional and not necessary.

Darrel, the poacher

Jun 07, 2023

@OrangecrushBronco I'm confused by your comment:
"very nice. Though I fear the future photos from someone who doesn't think to anchor into studs."

Because the track is anchored into studs every ~16 inches with lag screws, so it is very very strong.

I forgot how explicit posts must be on forums, i will update my instructions to say "lag screw into your studs"

Update: I added this:
Then some wood lag screws and washers, make sure to lag screw into your studs

My ceiling joists are 16" on center, so I have (7) total 3/16" x 1-3/4 lag screws into my studs/joists holding this up very strong!

Darrel, TK1215

Jun 07, 2023

djp
@OrangecrushBronco I'm confused by your comment:
"very nice. Though I fear the future photos from someone who doesn't think to anchor into studs."

Because the track is anchored into studs every ~16 inches with lag screws, so it is very very strong.

I forgot how explicit posts must be on forums, i will update my instructions to say "lag screw into your studs"

Update: I added this:
Then some wood lag screws and washers, make sure to lag screw into your studs

My ceiling joists are 16" on center, so I have (7) total 3/16" x 1-3/4 lag screws into my studs/joists holding this up very strong!

Oh, no you ARE correct and I get that. There are just people who see something and do it without reading nor thinking it through. I have seen people (try to) mount big screen TVs and other large/heavy items into drywall without as much as an anchor much less searching for studs. In project management you have to be aware of what contractors are doing at all times. Lol.

Supreme Leader of the Wandering but NOT Lost
2022 OBX Cyber Orange Metallic with random acutriments.

Darrel, djp

Jun 07, 2023

OrangecrushBronco
Oh, no you ARE correct and I get that. There are just people who see something and do it without reading nor thinking it through. I have seen people (try to) mount big screen TVs and other large/heavy items into drywall without as much as an anchor much less searching for studs. In project management you have to be aware of what contractors are doing at all times. Lol.

Yes, thank you very much for pointing this out...we must be explicit on the forums. To me of course you would go into studs, but to others it may not be the same. Especially for something like this, we must be explicit. Thanks for pointing this out

Darrel

Jun 08, 2023

djp
Yes, thank you very much for pointing this out...we must be explicit on the forums. To me of course you would go into studs, but to others it may not be the same. Especially for something like this, we must be explicit. Thanks for pointing this out

It IS a great write up and a solution I'm much more confident in then the weak looking options online.

Supreme Leader of the Wandering but NOT Lost
2022 OBX Cyber Orange Metallic with random acutriments.

Deano Bronc, Darrel

Jun 08, 2023

djp
Yes, thank you very much for pointing this out...we must be explicit on the forums. To me of course you would go into studs, but to others it may not be the same. Especially for something like this, we must be explicit. Thanks for pointing this out

I think your write up was fine! It was clear and concise!

Darwin had something to say about those who might try and attach said unistrut to a ceiling without locating studs…

I don’t have a chain hoist at this point so I’m thinking I will do this with a small electric winch that will mount to the unistrut via rollers…

Attachments

IMG_1511.jpeg 1170 x 1634 · 762.57 KB

Riding OB1, 23 4- door Outer Banks, SAS, MOD, MIC, Lux, Ordered 10/20/22, delivered 1/13/23

OrangecrushBronco, Darrel

Jun 08, 2023

I have all the parts but I am in limbo as I have a suspicion the ceiling joists are engineered beams and not solid wood. I'm afraid to drill into them for fear I might damage them. I can't figure out how to confirm. My ceilings are also full of solid foamed insulation, so I can't just open up some sheetrock and take a look.

Deano Bronc

Jun 08, 2023

#10

darinhouston
I have all the parts but I am in limbo as I have a suspicion the ceiling joists are engineered beams and not solid wood. I'm afraid to drill into them for fear I might damage them. I can't figure out how to confirm. My ceilings are also full of solid foamed insulation, so I can't just open up some sheetrock and take a look.

Oooo, yeah, that might be difficult to investigate. Maybe cut a large drywall chuck out, or if you have a hatch in the garage somewhere you can poke your head in and look.

Jun 08, 2023

#11

darinhouston
I have all the parts but I am in limbo as I have a suspicion the ceiling joists are engineered beams and not solid wood. I'm afraid to drill into them for fear I might damage them. I can't figure out how to confirm. My ceilings are also full of solid foamed insulation, so I can't just open up some sheetrock and take a look.

Are they joists or trusses? If trusses, as long as you’re not pulling an engine you should be fine…

You can get a little camera on a snake and push it through your sheet rock and foam insulation to get a look-see on what’s happening up above…

Riding OB1, 23 4- door Outer Banks, SAS, MOD, MIC, Lux, Ordered 10/20/22, delivered 1/13/23

Deano Bronc

Jun 08, 2023

#12

darinhouston
I have all the parts but I am in limbo as I have a suspicion the ceiling joists are engineered beams and not solid wood. I'm afraid to drill into them for fear I might damage them. I can't figure out how to confirm. My ceilings are also full of solid foamed insulation, so I can't just open up some sheetrock and take a look.

How old is your house?
Do you have any build pictures?
Are they building more houses in the area that you can look at, if newer build?
...just some ideas
Can you call builder?

Jun 08, 2023

#13

djp
Yes, thank you very much for pointing this out...we must be explicit on the forums. To me of course you would go into studs, but to others it may not be the same. Especially for something like this, we must be explicit. Thanks for pointing this out

Lol. Lowest common denominator.

Supreme Leader of the Wandering but NOT Lost
2022 OBX Cyber Orange Metallic with random acutriments.

Jun 08, 2023

#14

Bluestreak57
Are they joists or trusses? If trusses, as long as you’re not pulling an engine you should be fine…

You can get a little camera on a snake and push it through your sheet rock and foam insulation to get a look-see on what’s happening up above…

Joist... Funny thing is I have one of those and tried it - pulled a light fixture and snaked it through an opening in the mounting bracket - that's when I realized I wasn't going to get through the solid spray foam insulation.

Jun 08, 2023

#15

djp
How old is your house?
Do you have any build pictures?
Are they building more houses in the area that you can look at, if newer build?
...just some ideas
Can you call builder?

It's about 15 years old - no pics but I can see engineered beams in open areas of the attic close to that space. Joists are designed for loads from above. Not sure about pulling down on them.

Jun 08, 2023

#16

djp
Want to raise your hard top, and slide it out of the way?

Here is how....

10' Unistrut - this is your track

Link: Unistrut from Lowes

Even if you dont have room for a 10' track, get a 3' track. That way you dont have to perfectly back up, it will give you 3-feet of wiggle room :)

Strut Trolley - get this one on ebay as it has smaller wheels that will bypass the lag-screws you use to anchor in the strut. This trolley is rated for 250-lbs

Link: Trolley on Ebay

Chain hoist - i like this 1/4 inch one as it has a non-greased chain and is clean and simple

Link: Amazon Hoist

2" Tree Swing straps - You want 2" so it's wide and doesnt indent your weather seals, also the multi loop version makes it adjustable

Link: Amazon straps

(optional) Also get yourself a little bucket or bag, this will serve as your chain catch bucket/bag, so the excess chain doesnt droop down and rest on your hardtop.

Totally a vanity thing, as the chain on this lift is nice and soft, and I really dont think it will scratch or damage your top in anyway. But i had a bucket laying around so I used it.

Then some wood lag screws and washers, make sure to lag screw into your studs

My ceiling joists are 16" on center, so I have (7) total 3/16" x 1-3/4 lag screws into my studs/joists holding this up very strong!

Some sort of bolt to drill through the end of the strut, as a stopper so they trolley doesnt fly off :)

And voila ! Video below !!
Also if you want, toss your middle section on it too !!
(unfortunately, I cut my straps to size for just the top, so when i added the middle section i had to add some webbing... and thus the reason I now suggest the tree straps with the pre-sewn loops so you can adjust it)

Someone asked why I'm putting the middle section on the hard top now. The reason is, now that I am keeping my Bronco Bikini on 24/7, I can no longer stand in the middle of my vehicle and lift up the middle section. So I just can slide it onto the back clamshell and then take it up and away :)

Video: Under 2-minute install

Great job and very nice detailed instructions and links. Thanks for the ideas.

2023 Four-Door Wildtrak: Azure Gray, 2.7, Sasquatch, LUX, Tow, 2 Tops, Reserved 10/28/2021, Ordered 1/8/2022, Reordered for 2023 model year 10/13/2022, Build date received on 3/23/2023. Scheduled for week of May 15, 2023.

Jun 09, 2023

#17

That's awesome. Wish I had room in the garage for something like that. Truck would barely fit as it is.

Jun 09, 2023

#18

Mandogus
That's awesome. Wish I had room in the garage for something like that. Truck would barely fit as it is.

I don't have room to the side either, but this will make moving it back towards the wall away from the truck much easier - I got a 3' track and will use it to move it back a couple of feet to rest on a small shelf I'm adding just to take the load off the slots (and move it away from the window when I park forwards).

Jun 10, 2023

#19

Great project and instructions! As a former Facilities maintenance mechanic and old cowboy, I’ve always said, “Unistrut our friend”, and “Unistut is the equivalent of an erector set for adults”.
I just put an overland rack on my Bronco, and I want to build something similar to take it off so I can switch between that and my Thule topper.

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