Four Door Bronco Build Thread - Ford Bronco Forum
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post #1 of 48 (permalink) Old 10-31-2016, 05:01 PM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4
Four Door Bronco Build Thread

I have decided to start my build thread now that the rust repair is coming along. It is a 1995 Ford Centurion C150 (4 door bronco). It has a 351, E4OD, push button 4x4, with locking hubs. I will be converting it to a Bullnose (80-86). I bought a 84 F150 as a donor that provided a front clip for me, and bought new rockers, quarters, and inner wheel wells. I also picked up an 86 f150 bed trailer that donated inner tubs, and the gas tank area.

You can see my earlier thread here: http://www.ford-trucks.com/forums/14...nco-today.html

In that thread I swapped on a new tailgate, sport bumper, and new rims and tires. You can also see the rust we are dealing with.

Here is what I am starting with:







Cut the quarters off, rockers are pretty rough.



New ones mocked up



After some sand blasting



Test fit



Fabbed up part of that channel



End cap and other parts remade



Hit with some primer, welds need to be ground down still, and long cut has to welded up after the quarter is attached





Other side







Done

dash_cam and CDA 455 like this.

1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

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post #2 of 48 (permalink) Old 10-31-2016, 05:02 PM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4
Floor is pretty bad too



Donor 1986 f150 trailer



Minor cuts



Patch panel with new floor made, drain hole for rear heater added. Centurions have flat floors vs. broncos with ribbed floors, which is why the trailer didn't donate any of that.



Cut out



Mock up



Decided we needed the passenger side wheel tub too, so cut that out and added it in.




Other side









Other stuff



dash_cam and CDA 455 like this.

1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

1985 Bronco: Sold
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post #3 of 48 (permalink) Old 10-31-2016, 05:03 PM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4


Sandblasted:



Pinholes filled and hit with some POR 15, this was before we decided to add the new wheel tub.



Before and after



Quarters



Lower taillight







This is where we are at now. Need to finish up the drivers side floor, then the quarters will go on for good. Then we will panel bond in the inner wheel wells. Then the front clip will go on.

Here is the donor 1984 F150



Pulled the front clip and scrapped it



Sand blasted the core support and fixed a few cracks.



Here it after primer and paint



Hopefully all the metal work should be done soon. I'd like to get the the front clip on too before winter. It will be put in storage then. Next summer I want to finish body work and paint it blue. Long term plans involve swapping the body onto a 1 ton frame, Cummins, Bullnose interior, and more.

1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

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post #4 of 48 (permalink) Old 10-31-2016, 11:13 PM
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nice job on the metal work

did you paint all the inside of the new metal in all the closed spaces?
I did not on my old beater 78 bronco at rear of rocker and within 2 yrs it was starting to rust through again and I used 18ga steel
seems all the condensation inside the body got to it

I use a wd40 straw on a spray bomb can to get in all the tight places
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post #5 of 48 (permalink) Old 10-31-2016, 11:44 PM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4
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Originally Posted by trustyrusty View Post
nice job on the metal work

did you paint all the inside of the new metal in all the closed spaces?
I did not on my old beater 78 bronco at rear of rocker and within 2 yrs it was starting to rust through again and I used 18ga steel
seems all the condensation inside the body got to it

I use a wd40 straw on a spray bomb can to get in all the tight places
Thank you, my friend Cody is handling all the fab work, I help him wherever I can. I just don't have the skills to do this myself. All bare metal will be painted or hit with POR 15, there's not too many closed spaces on this truck, but if I see a spot I'll use your tip.

1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

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post #6 of 48 (permalink) Old 11-01-2016, 01:15 AM
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Butt welds on the quarters or overlap?

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post #7 of 48 (permalink) Old 11-01-2016, 01:50 AM
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post #8 of 48 (permalink) Old 11-01-2016, 10:53 AM
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Nice work so far! That was one rusty Centurion. Funny thing is the roof doesn't look that bad from the pics. Usually they are the worst part of a Centurion. Interesting that you are taking it back to 80-86 sheet metal - personally I like that style so I'll be interested in in seeing how it turns out.

I'll be doing a few of the same patch panels on my '84 here shortly.
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post #9 of 48 (permalink) Old 11-01-2016, 12:54 PM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4
Quote:
Originally Posted by forbye View Post
Butt welds on the quarters or overlap?
Butt welds

Quote:
Originally Posted by RadBronco View Post
dang! great build
Thank you!

Quote:
Originally Posted by Scoop View Post
Nice work so far! That was one rusty Centurion. Funny thing is the roof doesn't look that bad from the pics. Usually they are the worst part of a Centurion. Interesting that you are taking it back to 80-86 sheet metal - personally I like that style so I'll be interested in in seeing how it turns out.

I'll be doing a few of the same patch panels on my '84 here shortly.
The roof does has some rust, you can see it in the link I posted at the top. The seam where they joined the 2 trucks together has a little rust, but it's not bad yet. The windshield has rust under the lip and it leaks there, so that will need to be addressed. I love the 80-86 bodystyle! I had a 85 Bronco (my username), that I had to sell this summer in order to buy this bronco.
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1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

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post #10 of 48 (permalink) Old 11-01-2016, 01:18 PM
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wow. amazing rust repair. you are truly skilled.

threads like this make me really with I had a garage to work in

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post #11 of 48 (permalink) Old 11-01-2016, 01:40 PM
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man, you have put a ton of work into that thing. nice fab skills.
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post #12 of 48 (permalink) Old 11-01-2016, 02:15 PM
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Awesome build. Love seeing all the build pics. That's some serious repairs going on there. Keep the pics coming.

Oh and that's interesting about the flat floors in the rear. Gives me an idea on my 79. I've got rust spots in my rear floor. I may just get a flat piece and weld atop the existing floor.

Last edited by 79BroncoSpringTx; 11-01-2016 at 02:17 PM. Reason: Added comment
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post #13 of 48 (permalink) Old 11-01-2016, 02:31 PM
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Nice build!

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post #14 of 48 (permalink) Old 11-02-2016, 11:56 AM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4
Quote:
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wow. amazing rust repair. you are truly skilled.

threads like this make me really with I had a garage to work in
We are actually doing this in a tiny 1 car garage that has been turned into a dedicated shop, and the driveway

Quote:
Originally Posted by jermil01 View Post


man, you have put a ton of work into that thing. nice fab skills.
Quote:
Originally Posted by 79BroncoSpringTx View Post
Awesome build. Love seeing all the build pics. That's some serious repairs going on there. Keep the pics coming.

Oh and that's interesting about the flat floors in the rear. Gives me an idea on my 79. I've got rust spots in my rear floor. I may just get a flat piece and weld atop the existing floor.
Quote:
Originally Posted by Leer0604 View Post
Nice build!
Thanks guys!

1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

1985 Bronco: Sold
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post #15 of 48 (permalink) Old 11-02-2016, 12:14 PM
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Wow. After doing a lot of rust repair the last couple months (and not nearly as cleanly as this), I am impressed!! Looks fantastic. This will be a unique and really awesome rig when you're done. Following!

1979 Bronco Custom stock 351m, 33x10.5 BFG tires, Monstaliner paint job, work in progress!
Rusty Custom Build
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post #16 of 48 (permalink) Old 11-02-2016, 10:41 PM
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don't forget the front gas tank door!
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post #17 of 48 (permalink) Old 11-03-2016, 03:55 PM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4
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don't forget the front gas tank door!
Good eye, most people don't notice that. I cut the gas tank door area out of the donor bed, and will graft it into the new quarters. That was one of the reasons why I decided to buy a donor bed. 80-86 fuel doors are different than 87-96, so I couldn't use the old ones, and I couldn't find anyone who would let me cut up a bed for that spot.


Thanks @mrbollero !

1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

1985 Bronco: Sold
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post #18 of 48 (permalink) Old 11-08-2016, 08:43 PM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4
Got some more work done on the driver's side.



Here's a comparison shot



This piece of fiberglass was near the front of the quarter. Centurion just cut the inner quarter open, and glued this in, in order to add the second filler neck. Removed it and replaced with metal.





Before and after



Here is part of the new rear braces made.



We reinstalled the tailgate, aligned it, then welded part of the quarters back on to hold it in the correct place. Now he just need to finish welding up the floor, and it will be ready for the quarters to finally go on. Got the rocker capped off on the passenger side to match the driver's side. Also removed a bunch of useless brackets that were under there for the running boards, they were removed by the PO. Poked a hole in the gas tank a little while ago. Ordered a new one on Amazon for $56 with free shipping. Should arrive sometime this week.
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1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

1985 Bronco: Sold
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post #19 of 48 (permalink) Old 11-09-2016, 04:43 PM Thread Starter
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Bronco Info: 1995 C150 Centurion 4 Door Bronco, 351, E4OD, 4x4
Hit the inside with some POR15



Inside of the quarters painted too, little easier to do it before they go on the truck.



Driver's side wheel tub



Passenger side

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1995 C150 4 Door Bronco: 351, E4OD, 4x4, Bullnose conversion in progress
Build Thread: http://www.fullsizebronco.com/forum/...ld-thread.html

1985 Bronco: Sold
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post #20 of 48 (permalink) Old 11-09-2016, 05:29 PM
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great work...those spot welds look nice.
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