What Ive Been Up To (56K Warning) - Ford Bronco Forum
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post #1 of 127 (permalink) Old 03-21-2008, 09:07 PM Thread Starter
ate lug
 
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What Ive Been Up To (56K Warning)

Well, with the NE Chapter's trail ride only 3 weeks away, i figure now is a good time to spill the beans, since everyone's gonna find out soon anyway.



I might have accidentally chopped up my bronco



Ok, so it goes like this. Pay attention! This is gonna be a long one




Started out with this:


thats typical of every panel. Not quite as smashed up as larston's or acepaul's rigs, but close. the only thing left straight was the cowl! I found tears in the firewall, and even all the seams in the b-pillar were split open. It was pretty ugly. I decided she was worth giving a facelift, so here we go!


Step One: Disassembly


I swapped down to the 31s; its easier to work on it this way, even if it looks ridiculous



Started labeling wires, and then began removing the accessories




the ghetto sliders


...and then the interior!










mah bro takin a sawzall to the roof



Convertible?


Truggy?


parts truck?



More coming, dont go anywhere!


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post #2 of 127 (permalink) Old 03-21-2008, 09:13 PM
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Man you went to town with the sawzall

can't wait to see the rest!
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post #3 of 127 (permalink) Old 03-21-2008, 09:18 PM Thread Starter
ate lug
 
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Ok, Phase Two. I need a cab! Im not into being exposed to the elements 24/7, nor do i have any place indoors to store this thing, so building a buggy is out. Im not really into the Ranger cab idea (not yet, anyway), and i got this for free, so this is what im running!



1990 F250, 2wd, 302, 5spd. The harness couldnt possibly be any different from ine than it already is

So, the red interior, and the wiring harness has got to go, so i stripped this one down to bare metal, too.









Ok, so now, i need to get this thing from this frame, over to mine. Well, with it stripped down this far, myself & bnkrtstk were able to pick it up, carry it over, and set it down right where it needed to go!

So that gets us here:




Well, as you may recall from larston's & chuck's threads, while the a-pillar body mount bolts right up, the b-pillar mount does not. On the broncos the mount is outboarded, but on the f-series it is inboarded. I considered making the stock F-series xmember work, but decided it would require too much work to adapt it, so instead i just made a whole new one.

After taking a whole bunch of measurements a whole bunch of times, i ended up with this:





I removed the stock body mount bracket, drilled the holes out to 1/2", and bolted it up in the same spot




This gets the cab right at stock height. Thats right, i ditched the 3" body lift that ive had for years now.


So the cab is officially bolted to the frame!


Stay tuned, more coming!


88bronco: web / FSB || 96 bronco: web / FSB || 96 F250: web / FSB
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post #4 of 127 (permalink) Old 03-21-2008, 09:24 PM
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wtf did you do to the bronco

'85 Bronco Custom... RIP 01/24/2011 - Totaled By A Honda
'84 XLT - 302 - Stock - Flowmaster 44 - C6+208 - 32" Tires
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post #5 of 127 (permalink) Old 03-21-2008, 09:33 PM Thread Starter
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Ok, before we get carried away let me apologize for the crappy pics; i broke the digicam and didnt get anew one until much later on in the swap so some of the early pics aint so good. Anyways, moving on!



Ok, so i got the neighbvor to help my get the front clip up on the truck. Well, as it turns out, the bumper that i built around the 3"body lift,no longer clears the fender! Well, im not one to sacrifice ground clearance, so i just cut the bottom of the fender off, and whatta ya know, it bolted right on!



Movin on up! Now weve got this


I figured at this point i could put the doors on, and get everything re-aligned


Looks kinda like a truck again, altho nowhere near what it used to be




So, so previously i had moved the front-most body mount to the top of the frame rails, for tire clearance. Well this time i didnt want to hack up a nice clean core support, so i made a mini-body mount instead

The concept:


...and the finished product:



Ok, so now that the front-clip is firmly set inplace, it was time to move on to the fenderwells. I figured that since i had to cut them up toclear the 42s with 11" of lift, than now that i was down to 8", i have to cut another 3 or so inches out. Well, i was pretty close. Take a look at this:



Not even close to fitting!



But, it helped me to figure out just where i needed to cut, so i made the first rough cut:


I also starting trimming the core support back a bit



Ok, so the next step was to make tabs, so i could weld the two halves of the fender back together




To say im 'trimming' the fenders is an understatement!

So with that done, i yanked the clip again, and get all the tabs bent over to begin the welding


Bushwacker's aint got nothin on me!


Cut back so far the badge will have to be moved


Ok, to the driveway! Now, i dont own a mig or tig, so i had to do this the only way i could....with 1/16 6013 rod


Wasnt real pretty, but it got the job done




So then i grabbed a couple cans of paint, and rattled it one color so uit didnt look so damn bad


...and the 'finished' product, reinstalled on the truck


From there i rattled the rest of it, so now i have a single-color cab again!

More coming!


88bronco: web / FSB || 96 bronco: web / FSB || 96 F250: web / FSB
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post #6 of 127 (permalink) Old 03-21-2008, 09:42 PM Thread Starter
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Ok, next step: putting my interior in!

The F250's harness was unusable, so i had to put the bronco harness in. I took the opportunity to completely delete the ABS, cruise control, emissions & a/c, as well as some of the wiring for the bronco's tailgate.





the hacked-up core support painted black; also the trans & p/s coolers reinstalled


painted my spare grill black, as well as the chrome XLT lights


Now were getting somewhere!


interior coming together




I took both seatbelts apart, to swap my grey belts into the F250's spools since they are not interchangeable.




black dome light!


bronco buckets modified to work in the cab


...and the interior is 99% done! I even swapped in my power windows & doorlocks




Ok, next up we're headed back under the hood!


88bronco: web / FSB || 96 bronco: web / FSB || 96 F250: web / FSB
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post #7 of 127 (permalink) Old 03-21-2008, 09:54 PM Thread Starter
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OK, with the fenderwells gone and no way of ever going back in, i had to do something with the airbox. Well, the solution is the '86 box! Gets it tucked up over top of the d.side valve cover


Later on i intend to make a snorkel for it that pops thru either the hood or cowl, but for now this will work fine.

Then, while i had all that available room, i ditched my manifold for a set of shortys



But, that is just one of many problems solved. Take a look at this; i cut the fenders back so much the heater box sticks out!


Since im not a whizz when it comes to bodywork, i ended up cheating, and going this route instead:




....and a coat of paint. Hopefully it will work out in the long run, we shall see!


From the inside; not much room left for anything!




And the d.side....i had to make a panel to fit around the bulkhead fitting+the ECM connector. Down the road i might move the ECM and re-do this section.




It looks like it sticks out, but youll notice it doesnt actually stick out any further than the firewall, so i think it will clear fine.



So, with that done, i could start putting more stuff back under the hood. For starters, here is the new location for my overflow tank, and my remote trans filter:



Got the electric fan reinstalled


starter relay, mega-fuse for the 3G, and my relay box


remote reservoir for the steering


...and the OBA manifold


This gets the cab 99% done. it runs & drives, so that means i can shift my focus to the back half of the frame. To be continued!


88bronco: web / FSB || 96 bronco: web / FSB || 96 F250: web / FSB
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post #8 of 127 (permalink) Old 03-21-2008, 09:58 PM
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Man thats alot of work but its looking GOOD!. Keep it up.
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post #9 of 127 (permalink) Old 03-21-2008, 10:04 PM
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that looks awesome but it's not a bronco

1995 Ford Bronco Eddie Bauer 351W 2.5" RC Front Lift. JBG 3" Rear Springs. 17" M/T Classic III's and 285/70/17 Toyo Open Country A/T II, 4.56 gears trac-loc f/r. Street Toy
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post #10 of 127 (permalink) Old 03-21-2008, 10:07 PM
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This is one I've been waitin' on!!!

Looks awesome Kevin
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post #11 of 127 (permalink) Old 03-21-2008, 10:07 PM
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lookin good kev

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post #12 of 127 (permalink) Old 03-21-2008, 10:09 PM
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Been wondering when you would get around to posting this.





Quote:
Originally Posted by ToddACimer View Post
that looks awesome but it's not a bronco
I think we can cut him some slack.
(Coming from me, well, )

Eastern 4 Wheelers www.eastern4wheelers.org
the thing:
'95 XLT Frame, 351, E4OD, Firewall, Floor, Seats.
Everything else GONE.
One tons, 4.56's ARB's 38.5 SX's. No Body. Full Cage. Etc.Superford Pics
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post #13 of 127 (permalink) Old 03-21-2008, 10:09 PM
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Dude--that's a lotta work! How long have you been working on it?

My SuperFord
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post #14 of 127 (permalink) Old 03-21-2008, 10:12 PM
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the end/current product is pretty kickass if I say so myself (Ive already seen it)

~Dave~
1998 Jeep Wrangler, 5.5" lift, wheels, tires and all the other cool stuff.
1997 Dodge Ram 5" lift, 35"s, 396 stroker, stereo, and some random things
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post #15 of 127 (permalink) Old 03-21-2008, 10:19 PM Thread Starter
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I considered building a flatbed. Really, i did. But, in the end, I wanted something with style. And for that, you just cant beat a stepside! Enter the secret weapon!


I removed the busted fiberglass fenders,and the rotted out xmembers, and took what was left of the bed & got it up on the frame. Well, its a tad too long



But man if that aint a sexy tailgate!



So after some careful measuring, i determined that the bed needed to be 15" shorter. Specifically, 8" from the front, and 7"from the back. So i busted out the sawzall (again) and went to town!

the shortened pas fender in front of the d.side, shows the difference in length


The next step was to take the stake pockets, cut the sheetmetal off the back of them and then re-spot-weld them to the newly shortened fenders. Fortunately, a buddy has a spotwelder that he lent me to do this job. And damn are they cool!





then i busted out the dremel, made some choice cuts, and viola, the stake pocket was usable again!




and that was basically all the fabwork for the fenders. Neat thing with these beds is, the fenders bolt to the header and the rear wall, so it was just as simple as redrilling the holes and the bed simply bolted back together, 15" shorter






Ok, so next up was to make some new xmembers for the bed. Settled on 4, since stock the bed has 5.


Then i bought a pile of 1*3s, and started making a new floor








...and heres something cool....put the toolbox on the rails, and slid a tire in. It *just* fits



Ok, anyways......i trimmed the floor to match the fenderwells


and got the bed set up there, so i could move it to the driveway for some welding


First things first, narrow the bumper. Cut ~7" off each side, so figure the bumper is now roughly 18-20" narrower than a stock bronco bumper. Ill have to measure that tomorrow.


Then i cut the rear stake pockets, and then the flat panel in the back as well


So that gets us here, but the bed still isnt bolted down!


I settled on 6 mounts for the bed. 4 in the back, and two up front. Out back they are short, only 2" tall, so i made em like this

Theyre not perfect, but they work so im happy.
Up front, the mounts had to be 5 3/16" tall, so i put a little more effort into them



Heavy bead inside, light one outside, ground smooth, to make them appear as if they are on piece and not 4


Coincidentally, they ended up being dead center on this xmember


...and the other 4


So with those done, they got painted, and the bed installed for the final time.
From there i used a piece of 2" filler neck hose from national, plus a 1 7/8" 45º exhaust fitting, plus halfpof my stock filler neck, to get to the inside of the bed. This is still a work in progress.





i intend to brace this up somehow, just not sure yet



So this gets me caught up to today, when the toolbox got bolted in


I also decided that there is nothing left to do that will be harder to do with the iroks on, so they finally made it back onto the truck







Right now im in crunch mode....i need to relocate the batteries to the bed, re-finish the OBA and get a totally new exhaust system on it before the NE Chapter ride at Rausch Creek in 3 weeks. After that im going to go back and finish off whatevers left, and then i can start playing with the suspension again.

Sooo......flame away!


88bronco: web / FSB || 96 bronco: web / FSB || 96 F250: web / FSB
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post #16 of 127 (permalink) Old 03-21-2008, 10:20 PM
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I just shed a tear. Another bronco gone.

oh well, looks good anyways.

Quote:
Originally Posted by Ragged_ol_86 View Post
Listen to death metal, drink beer, punch babies, stuff puppies in wood chippers and blow an 8 ball of coke all while getting a blowjob. Makes life less miserable.
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post #17 of 127 (permalink) Old 03-21-2008, 10:23 PM Thread Starter
ate lug
 
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Wow, lotsa replies



Yep, sorry its not a bronco, but the size of the body just doesnt do too well in the rocks. But, i still wanted to stay semi-close to its roots, which is where the '90 cab came in; im still running my original grill, cowl, and interior



Ogeechee....i started this project in july Apparently i work slow



Thanks for the compliments tho guys its been one hell of a long project, but the end is finally in sight.


88bronco: web / FSB || 96 bronco: web / FSB || 96 F250: web / FSB
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post #18 of 127 (permalink) Old 03-21-2008, 10:24 PM
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how are you going to do fenders on the back, anyway?

Quote:
Originally Posted by Ragged_ol_86 View Post
Listen to death metal, drink beer, punch babies, stuff puppies in wood chippers and blow an 8 ball of coke all while getting a blowjob. Makes life less miserable.
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post #19 of 127 (permalink) Old 03-21-2008, 10:24 PM
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Quote:
Originally Posted by reptillikus View Post
Sooo......flame away!
Un-do everything and go back to the old Bronco Body.


































j/k Looks like nice fab work. Get it weighed.

Eastern 4 Wheelers www.eastern4wheelers.org
the thing:
'95 XLT Frame, 351, E4OD, Firewall, Floor, Seats.
Everything else GONE.
One tons, 4.56's ARB's 38.5 SX's. No Body. Full Cage. Etc.Superford Pics
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post #20 of 127 (permalink) Old 03-21-2008, 10:27 PM Thread Starter
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I will, once its done. Shame i didnt weigh it before i started the swap.



Quote:
Originally Posted by Maelthra View Post
how are you going to do fenders on the back, anyway?
Im not going to.


Actually, i might make something removable so i can street it, but i dont want a fender out back, itll just get smashed on trees.


88bronco: web / FSB || 96 bronco: web / FSB || 96 F250: web / FSB
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