79 Rusty Custom build - Page 4 - Ford Bronco Forum
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post #61 of 113 (permalink) Old 10-22-2016, 11:12 PM Thread Starter
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Drove the truck out of the garage today and took a few pics. Also finally got around to changing the plugs and wires- what an incredible difference! It ran like a "new" truck! The old spark plugs were super crusty and even rusted on the outside but they came out fine.


Shows the texture a bit.


Very sunny day so this one is a bit washed out.






You can see a few spots I missed but I'll hit those later.

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post #62 of 113 (permalink) Old 10-31-2016, 06:38 PM
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You are right! Pretty similar condition of the floors. I have a ton of that JASCO stuff left over from a BMW build I had considered for 5 minutes. I am sure I will have to go to town on it and do lots of patching like you did. How strong is the now non-corrugated section behind the front seats now that you patched it?

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post #63 of 113 (permalink) Old 11-01-2016, 12:09 PM Thread Starter
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You are right! Pretty similar condition of the floors. I have a ton of that JASCO stuff left over from a BMW build I had considered for 5 minutes. I am sure I will have to go to town on it and do lots of patching like you did. How strong is the now non-corrugated section behind the front seats now that you patched it?
Yeah, that Jasco stuff is amazing. I bought 3 bottles and only used maybe half of one.

So, that new flat section is NOT strong- it flexes a bit. I have a piece of that section cut from the bed of a donor bronco at a junkyard, so my plan originally was to use it, but in the end the flat piece was just way easier. I might end up splicing in the correct section for strength, but for now I plan to add a piece of angle iron under the floor, welded to the frame. It only flexes at the very back because I cut out the little ramp up in order to put a door in for the under floor storage. If it was welded all the way around, it probably wouldn't flex.

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post #64 of 113 (permalink) Old 11-01-2016, 12:16 PM
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Yeah, that Jasco stuff is amazing. I bought 3 bottles and only used maybe half of one.

So, that new flat section is NOT strong- it flexes a bit. I have a piece of that section cut from the bed of a donor bronco at a junkyard, so my plan originally was to use it, but in the end the flat piece was just way easier. I might end up splicing in the correct section for strength, but for now I plan to add a piece of angle iron under the floor, welded to the frame. It only flexes at the very back because I cut out the little ramp up in order to put a door in for the under floor storage. If it was welded all the way around, it probably wouldn't flex.
Very cool! Great intel there. Since I am not doing the box, then I can just do a flat piece and weld all the way around and if there is movement, angle iron down there makes sense too!

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post #65 of 113 (permalink) Old 11-02-2016, 07:05 AM Thread Starter
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Very cool! Great intel there. Since I am not doing the box, then I can just do a flat piece and weld all the way around and if there is movement, angle iron down there makes sense too!
Yeah, that would work for sure. There isn't all that much space between the frame supports, so even if you step square between them you're only maybe a foot away from a support. I used 16 gauge but if you REALLY want it to be solid 14 gauge would last forever.

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post #66 of 113 (permalink) Old 11-02-2016, 08:10 AM
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wow, she looks much better now that she's all cleaned out and painted. nice job

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post #67 of 113 (permalink) Old 11-02-2016, 10:14 AM Thread Starter
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wow, she looks much better now that she's all cleaned out and painted. nice job
Thanks! Yeah, it's a different truck. Gotta replace a brake line that rusted out and is spewing fluid this weekend and replace the leaking pinion seal for the 9 inch. On pause right now because I got in a hurry and cut my hand open, so my 14 stitches are keeping me from doing much.

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post #68 of 113 (permalink) Old 11-02-2016, 10:31 AM
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Thanks! Yeah, it's a different truck. Gotta replace a brake line that rusted out and is spewing fluid this weekend and replace the leaking pinion seal for the 9 inch. On pause right now because I got in a hurry and cut my hand open, so my 14 stitches are keeping me from doing much.
Pics!

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post #69 of 113 (permalink) Old 11-02-2016, 12:57 PM
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Give blood to the Bronco Gods as a sacrifice, yeah pics of the damage!
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post #70 of 113 (permalink) Old 11-14-2016, 02:34 PM Thread Starter
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Finished painting the front grill and components this weekend. I used plastidip so if I don't like it I can just peel it off. Turned out great though, so I'll leave it for now. Also drove it around town and everything seems to be working as it should. Some lifter tick and blue smoke at startup (likely old valve seals), so a rebuild or engine swap will be in the future, but I'm just going to enjoy it for now. Sorry for the poor camera quality- I'll get the good camera out when I get the doors on (weather in the 60s!).





These next two are from a week or so ago- hadn't finished painting some of the grill shell.




Next up:

Leaky pinion seal

Get creative to fix the middle air/heat vent tubing behind the dash.

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post #71 of 113 (permalink) Old 11-14-2016, 02:52 PM Thread Starter
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For those who want to see what a hole saw drill bit does to fingers.

14 stitches

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post #72 of 113 (permalink) Old 11-14-2016, 07:42 PM
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For those who want to see what a hole saw drill bit does to fingers.

14 stitches
Well done! That looks like it hurt like the Dickens.

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post #73 of 113 (permalink) Old 11-14-2016, 08:16 PM
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I generally like to keep my fingers away from the spinny part
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post #74 of 113 (permalink) Old 01-06-2017, 09:02 AM Thread Starter
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Wow, sorry guys, busy holiday for me. Fortunately I was able to find some time to work on the truck and get a few things done. Below are some before/after pics that I took a couple months ago, and I'll post more soon.

The big things that I've completed recently:
-Installed some aftermarket gauges so I know what's really happening.
-After flushing the coolant, the radiator sprouted leak after leak, so I went with a Champion radiator off of Ebay. It fit like a glove with the exception of one of the bolts that holds in part of the AC system, but it was no major problem. Truck runs perfectly now, stays right at 192 when hot, but of course the real tests will come in the summer.
-I replaced the pinion bearings on the 9" in the rear. This was a big-ish project for me as I'd never even removed a driveshaft. It went pretty smoothly though, and I used these two resources to help me out:
DIY Ford guide
-I had the old bald tires replaced with my new 33x10.5 BFGs- looks so much better! I was worried I wouldn't like skinnier tires, but I think it gives the truck a slightly leaner look, which I like. Will post pics of that soon.
-Re-attached the doors and used new door hinge pins from NPD so that they can be somewhat quickly removed and replaced.

The truck now runs and drives great- I'll be using it when the weather is decent.

Future projects:
-Front tires need a little toe alignment- one tire looks cockeyed slightly
-Working on a simple overhead console to hold a couple speakers and switches.
-Lots of work on the interior, including replacing the seats (I found a couple cheapies in good shape from the JY that I'll try to modify to fit), mounting speakers, etc
-Going to fab some 1/2 doors
-Build a tonneau cover
-Mount some door panels and bed-side panels
-The rear brakes may need a little work, but it's stopping fine right now. Going to keep my eye on them. Ordered new wheel cylinders just in case- pads are basically new
-Need to fix the venting behind the dash, as well as the selector as it doesn't seem to be diverting the air from defrost

Pic before tires:
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post #75 of 113 (permalink) Old 01-06-2017, 06:35 PM
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Looking good, movi'n along.
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post #76 of 113 (permalink) Old 01-07-2017, 02:13 AM
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Thanks guys.

The body is definitely got some rust issues. It's hard to see, but the driver's rear fender is just rusted away under the trim. Not as bad under the pass. side. The floor is also pretty rough- going to need new floor pans and some work in front of the back seat. Nothing too unexpected though.


That's definitely at the top of the list!

Could be the trailer special- it has a really thick sway bar on the back, but maybe that's standard. It has a lot of the original documentation in the glove box (I'll definitely take a picture of it), so I'll have to look at that more closely.
Nope, rear sway was not std. My first bronc, 78 custom with only option two-tone paint, had only front bar.
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post #77 of 113 (permalink) Old 01-07-2017, 06:19 PM Thread Starter
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Took the BKO for a short spin tonight to test it on the interstate. No issues, but it did drip a noticeable amount of fluid from the AC drainage hose. My truck has the AC all installed but the belt isn't hooked up to the compressor. I ran heat the whole way and did put it on defrost for a few minutes just to fiddle with it, so I figure there might have been some condensation in there. If this isn't normal, let me know!

When I got to where I was going and got out I just had to take some pics. Not the best cause my phone sucks, but you get the idea.





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post #78 of 113 (permalink) Old 01-09-2017, 09:58 AM
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Looks great. Glad the test drive was good!
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post #79 of 113 (permalink) Old 02-05-2017, 01:20 AM
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How much did the liner spray set you back?

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post #80 of 113 (permalink) Old 02-22-2017, 02:39 PM Thread Starter
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How much did the liner spray set you back?
Sorry for the delay- it was about $300 and it was actually a roll-on, not spray. Here's a link to the writeup I did if you want more info.
Painting with Monstaliner
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