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

djp
Jun 06, 2023

Rank III

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.
  • [$59] Chain hoist - i like this 1/4 inch one as it has a non-greased chain and is clean and simple
  • [$15] 2" Tree Swing straps - (8-foot -- but I tied knot in mine so they are about 7' now)
  • (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

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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)
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Chief Ron, Pygmy Warrior

Rank IV

Jun 11, 2023

#20
This is a nice simple design, keep in mind, the 2 door top approx 60lbs, 4 door top lighter still, add the cheap electric hoist lighter than a chain hoist - https://www.harborfreight.com/mater...60S1CMfC-gVVEdEf71qy9bGNvxiOf7rhoCQm8QAvD_BwE

Rank II

Nov 01, 2023

#21
Finally finished my DIY hoist - well almost, planning on replacing the 2x4s of the floating shelf with aluminum rectangle 1x2s but here's my setup:

Also want to set up something to keep the hooks elevated until the rack is fully lowered onto roof (probably some paracord tied across that the hooks can latch onto)- those hooks are super heavy and don't want them clanging around on the top or windows. This thing is WAYYY overkill but it was a fun project I got to work on with my brother and it didn't cost nearly what one of the in the box setups run.

PXL_20231015_154000004.jpgPXL_20231004_032240233.jpg
James M., Ditchrunner

Rank II

Jan 08, 2024

#22
Looking at electric hoists and ideasfor my garage.I have13’ceilings and a large LVL beam that is 12’ at lowest point.

Can someone let me know the total height from your hoist top to hardtop bottom? I want to see if it will hang above my garage door. I have about 3’8” above my door. I can use maybe just use a hoist with a top hook and remote bolted to the middle of the beam as not to lag screw into the bottom. LVL specs.

Rank III

Jan 08, 2024

#23
from top of hook, just under my C-channel is about 3'3. I'm sure i can tighten up all of the straps to make it < 3'

That hoist from top hook to bottom hook is about 11".
And hard top itself i think is only 22".

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Deano Bronc

Rank II

Jan 08, 2024

#24
from top of hook, just under my C-channel is about 3'3. I'm sure i can tighten up all of the straps to make it < 3'

That hoist from top hook to bottom hook is about 11".
And hard top itself i think is only 22".

1704740383488.png
Thank you so much djp. Huge help!

Rank II

Jan 09, 2024

#25
I am going to do a track with a remote electric hoist. I have to mount it to a large lvl in the middle 1/3 of the middle 1/3 of the beam. Should be interesting.

Rank II

Jan 09, 2024

#26
Looking at electric hoists and ideasfor my garage.I have13’ceilings and a large LVL beam that is 12’ at lowest point.

Can someone let me know the total height from your hoist top to hardtop bottom? I want to see if it will hang above my garage door. I have about 3’8” above my door. I can use maybe just use a hoist with a top hook and remote bolted to the middle of the beam as not to lag screw into the bottom. LVL specs.

Mine is a 10' ceiling - I have a couple of inches clearance to drive under the suspended top even with the aluminum support bars.
Ben221

Rank 0

Jun 06, 2024

#27
Do I need 2 of the trolleys for this build? How does the hoof from the hoist connect with the trolley(s)?

For those of you who used an electric hoist with this build - how did you mount it? Are you happy with it? I was wondering specifically how well it maintains its hold

Thanks. I never even thought of what a mess people's garages looked like as they were cruising with the top and doors off lol.

Rank III

Jun 06, 2024

#28
Do I need 2 of the trolleys for this build? How does the hoof from the hoist connect with the trolley(s)?

For those of you who used an electric hoist with this build - how did you mount it? Are you happy with it? I was wondering specifically how well it maintains its hold

Thanks. I never even thought of what a mess people's garages looked like as they were cruising with the top and doors off lol.

1 trolley only.

I took a step bit and just made a center hole.
Originally I just had a ring in there but i wanted the top as high as possible. Thus by drilling a center hole i was able to raise it all up a few inches.

I suggest the manual chain hoist, its is easy, nearly zero effort to lift and lower. It's clean, quick and simple.
With the electric hoist your top will likely hang about 10" lower. I wanted mine as high as possible.

(that red bucket is a chain bucked to catch my chain droop, so it doesnt sit on top of my bronco)

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Deano Bronc

Rank III

Jun 06, 2024

#29
I also posted this photo on the original 1st posting.

46" from ceiling drywall to bottom of top.
So that is: Track + Trolley + Hoist + Top == total hanging length of 46"

1717676113597.png

Rank II

Jun 06, 2024

#30
I am going to do a track with a remote electric hoist. I have to mount it to a large lvl in the middle 1/3 of the middle 1/3 of the beam. Should be interesting.

Did the same.

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Team Jeff!

Jun 06, 2024

#31
My concern with hanging the top by the straps is that it will damage the seals. Does the straps deform the seals once you take them off?
2022 Bronco Badlands, 4D, Hot Pepper Red, 2.7, Squatch, Lux, and MIC.
7/13/2020 10:04pm reservation. Blend 6/16/2022 Delivered 6/26/2022.
Dealership - Stephen's Auto Center.
Rydfree

Rank II

Jun 06, 2024

#32
The trick is to reduce the total length of the hoist and straps to get it up high and out of the way. I just used ratchet straps from the front top bolt hole and the rear has a little bracket next to the rear window shocks and sniffed it up. Going to make a strap that goes from edge to edge of the rack mount slots in the coming days.
Deano Bronc

Rank III

Jun 06, 2024

#33
My concern with hanging the top by the straps is that it will damage the seals. Does the straps deform the seals once you take them off?


No, this is the 2nd year I've hung my top and with the 2" "tree swing" straps, I have no deformation
Deano Bronc

Rank III

Jun 06, 2024

#34
No, this is the 2nd year I've hung my top and with the 2" "tree swing" straps, I have no deformation

@Deano Bronc
Added some pictures for you, showing you zero deformation with the wide straps

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Deano Bronc

Don't Follow Me ,I'm about to do something Stupid

Jun 06, 2024

#35
My concern with hanging the top by the straps is that it will damage the seals. Does the straps deform the seals once you take them off?

Kinda hard to see in this pic but the trick is to rig the ropes/strap so that it angles away from the seal and never touches it. Mount the top pulleys a little wider than the actual top.
2Dr Badlands - MIC - Area51 - 2.7 Auto - MGV - Headliner - High Pkg
Reserved 7/20/20 Delivered 5/6/23
"Ford said, hey we're gonna fulfill all reservations and pre-orders before we build stock units."
Deano Bronc

Rank II

Jun 06, 2024

#36
My concern with hanging the top by the straps is that it will damage the seals. Does the straps deform the seals once you take them off?

Or you can build a floating shelf to support the top from the bottom and taking some of the stress off the hooks/straps. See my post above. I'm at 45" from ceiling to top of floating shelf. More pics of my build album in the link:
https://photos.app.goo.gl/Eerm1DfNpW1yvwyw7
ckelly33, Deano Bronc

Rank 0

Jun 07, 2024

#37
Or you can build a floating shelf to support the top from the bottom and taking some of the stress off the hooks/straps. See my post above. I'm at 45" from ceiling to top of floating shelf. More pics of my build album in the link:
https://photos.app.goo.gl/Eerm1DfNpW1yvwyw7

That's impressive. What are the first few pics showing? Did you supercharge your hoist ?? 😂
djp, Johnny Mo

Rank II

Jun 07, 2024

#38
That's impressive. What are the first few pics showing? Did you supercharge your hoist ?? 😂

Haha - no not a supercharger - just extending the length of the remote cable to 20' or so - (apparently since it is a high voltage cable there's some nuance to it), the standard 6' was gonna be way too short for maneuvering around the top solo and making sure it was all separating and landing nicely. It was a fun project...way overkill, but that's where my ocd kicks in and takes over.
Deano Bronc

Rank II

Jun 12, 2024

#39
I use 4” buckles from tie down straps and just a random strap. I thrown the roof rack cross bars on top to balance it
IMG_6867.jpeg

Iuse
djp, Deano Bronc

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