1978 bronco ranger XLT revival - Page 4 - Ford Bronco Forum
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post #61 of 175 (permalink) Old 11-22-2015, 05:52 PM Thread Starter
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Picture of the shop where the bronco will be staying

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post #62 of 175 (permalink) Old 11-26-2015, 08:31 AM Thread Starter
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Spent some time digging for rust, I didn't have to dig very long



The floor and the cab support are both rotted out pretty bad in this spot. This is what came out after all the trimming



And after a little fab work (perks of doing this in a fab shop)





After all that I'm not happy how it fit in the bottom along the rocker so I scrapped it and started over with a better fitting one

Going to start on the passenger floor pan today. I don't have the replacement panel yet but I can at least trim the rust out and see if I need any more parts
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post #63 of 175 (permalink) Old 11-26-2015, 07:29 PM Thread Starter
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Since I don't do holidays I got some more work done on the bronco.

A friend sold me these seats for cheap and since my factory ones were trashed I figured I'd give them a go



I'm not sold on it yet, depends on the overall outcome of the bronco if they stay. But with that in mind I modified the seats to fit the factory bronco seat tracks so nothing can't be reversed.



This took some work to make right. Due to the height of the seat it has to be leaned forward before you can flip it forward but it does allow access to the back.

Tomorrow I am going to start on my front tube bumper. I've been drawing up some plans and doing the trig to get my angles right. It's to bad our burn table is down or else I'd just put the numbers in the computer and let it burn the parts out. So I will just lay it out by hand and do it the old fashioned way
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post #64 of 175 (permalink) Old 11-27-2015, 06:49 PM Thread Starter
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Got more done today. Waiting on parts I tackled the front bumper. I'm building a tube bumper to replicate the bubba bumper but with some of my own ideas







I have a lot more to do to it. But it's coming out decent
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post #65 of 175 (permalink) Old 11-28-2015, 01:06 AM
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not a bad start kanuck. I'd like to come up with something similar someday.
I've got the lighting tube bumper in the rear already, so it just makes sense.
look forward to seeing how it comes out.

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post #66 of 175 (permalink) Old 11-28-2015, 08:53 AM Thread Starter
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I'm having second thoughts on it. I almost want to do factory bumpers with the factory tire carrier. This bronco has me torn between the mall crawler pre-runner look vs a clean factory look lifted a bit
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post #67 of 175 (permalink) Old 11-28-2015, 10:55 AM
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So Kanuck....if those are 33" tires and no lift, I'd say save up and do the 35" and 2" lift. Big tires stuffed up under looks bad ass!!......Great project.
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I wrench on it because I have to....
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post #68 of 175 (permalink) Old 11-28-2015, 01:11 PM Thread Starter
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See I like to see a bit of fender gap, I am going to do a 4" lift on 35s. The 35s I am going with measure out big so it will be alright I think

So after looking at some clean bronco pictures I am going to put my factory bumper back on. I will keep working on the winch bumper but it wont be put on any time soon. Leaning more towards going clean chrome bumpers, clean trim, and if the guy on here gets back to me I will be getting the free wheeling strip kit if he has them. I am getting indecisive with this poor bronco. Half of me wants to do a pre runner setup but the other half wants to do the clean factory setup
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post #69 of 175 (permalink) Old 11-28-2015, 02:17 PM
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clean factory is the way to go, imo. I'm wondering... the newer model bumpers are great for hiding the winch setup and maintaining that stock, clean look... but not sure how well or even IF you could get away with stashing a winch behind the smaller 78/79 bumper.


oldrojo: I had 35's w/3" body lift on my old '89 and kinked fenders and tore side lugs when I took it off road. The stuffed tire deal may look cool, but if you ever get off-road, it's completely impractical. I put 33/12.5/15 SSR Swampers on the ol' lady's '78 XLT and it looks good and works fine but it's not really an off-road rig but I wouldn't go any larger.

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post #70 of 175 (permalink) Old 11-28-2015, 03:33 PM Thread Starter
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I hid a winch behind my 96 bumper and it worked well. I wouldn't do that to the 78, if I had to have a winch id do a front receiver and go that route

Today's progress, got my pre made piece for the cab support



The support to rocker panel fit up is perfect and I'm happy with it. Now to fix the floor above it. Front floor pans are on there way so that's next
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post #71 of 175 (permalink) Old 11-28-2015, 07:18 PM Thread Starter
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Got my patch in, that being said this is my first time doing this kind of stuff. I am a welder/fabricator/pipe fitter but I've never done sheet metal work. So be kind, I burnt thought a spot but the seam sealer will take care of that

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post #72 of 175 (permalink) Old 11-29-2015, 11:13 PM
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my floors and panels look just like yours a lot of work ahead of us!!!
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post #73 of 175 (permalink) Old 11-30-2015, 08:10 AM Thread Starter
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It won't be to bad to fix. Once my repair pans come in for the front I will basically be done with my floors. Then on to the rear quarters
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post #74 of 175 (permalink) Old 11-30-2015, 12:36 PM
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Hey Kanuck that looks pretty good. Are you going to weld it solid all the way around?
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post #75 of 175 (permalink) Old 12-01-2015, 04:10 PM
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Quote:
Originally Posted by kanuck15 View Post
Already have ordered the correct engine stands for the 390 along with headers and the 390 power steering bracket.
Mind sharing the part numbers for these three items? I'm about to need to same for my set-up...
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post #76 of 175 (permalink) Old 12-01-2015, 08:03 PM Thread Starter
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I'm not welding it solid, no reason to considering all the sheet metal is spot welded and seam sealed. This will be the same. The heat from welding it solid would kill the floor

I don't have part numbers but it's factory f150 73-77 with a 390. The power steering bracket is factory 390 truck. I found them all on eBay
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post #77 of 175 (permalink) Old 12-03-2015, 07:26 PM Thread Starter
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So I am in deeper than I thought. Looks like both front cab mounts need replaced. Along with the rear body mounts and the rear most cross member. This is by no means throwing in the towel, just gonna have to spend some more time before it's ready for the fun stuff
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post #78 of 175 (permalink) Old 12-03-2015, 10:25 PM
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I disagree with your thoughts on the heat of welding the floor solid, destroying the floor.
you just have to take a minute between and do short spots at a time.
I just went around and around on the floorboard patch of my '73, until it was all closed up.
then ground the piss out of it to clean it all up and did a few heat shrink spots to tighten it all up so the big patches didn't have that "pop-can" effect when stepping on/off the floor.





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post #79 of 175 (permalink) Old 12-04-2015, 07:27 PM Thread Starter
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After patching a piece near the door latch and welding it solid I figure I probably could do that. I just don't see the need. If Ford saw fit to only spot weld these panels in why weld them in solid?

At best I may stich weld them but not solid. To me that is over kill and putting a lot of unneeded work into it
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post #80 of 175 (permalink) Old 12-04-2015, 10:05 PM
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my thoughts on solid welding patches, I can see spot welding the edge where it originally was
,but anywhere it was cut into a piece, I think it should be solid welded to form a single piece as original for strength reasons
I have seen many spot welded patches crack sealant and rust soon as they flexed when they shouldn't have
I solid weld everything and never had an issue with too much heat
just have to be careful and not set mig too hot, and use the shielding gas,flux core does not work too well from my experience unless metal is clean and shiny new,and even then it was just so so
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