Rept's Super Slow Re-Re-Rebuild (90) - Page 2 - Ford Bronco Forum
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post #21 of 180 (permalink) Old 08-05-2016, 02:03 PM Thread Starter
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I hear ya on that; most of july it was well over 100ļ inside at work every night, by the time I got home from work I was too beat to do anything, so this thing pretty much sat idle in the garage for weeks.
Now I need to get as much done as possible before it gets cold because the tent isn't snow-rated. Fortunately the garage is well insulated, and I just picked up a pellet stove for it, so itll be toasty in there this winter
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post #22 of 180 (permalink) Old 10-23-2016, 01:26 PM Thread Starter
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Wait, what? An update?

So a hot humid summer filled with mandatory OT has kept me from making much progress, which left me reluctant to update this thread. however at this point I think ive got something worth posting.

I finished stripping the donor frame. Saved some brackets, body mount parts and the rear leafs, and chopped up the rest.




I succeeded in removing this piece of box tubing from the rear of the body, that the previous owner welded in in place of body lift pucks. he did a pretty nice job, but im not running a body lift so it had to go.


Sand blasted and painted the battery tray + air box parts




And I finished sands blasting the underside of the tub
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post #23 of 180 (permalink) Old 10-23-2016, 01:34 PM Thread Starter
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This is where it starts to get cool (IMO, anyway). I bought a spray gun from Al's Liner, along with their HNR (heat & noise reducing paint), and their spray-on bedliner.

Spray gun. This is more like an undercoat gun; it has a 6mm(!) nozzle


The Heat & Noise Reducer is some kind of ceramic paint; its supposed to be pretty good at what it does so I figured why not.

The test patch, dialing in the gun mostly


...and the whole underside sprayed! Went up into the wheel wells, and up the firewall


It goes down pretty easily


slight texture to it; I suspect with some more adjusting I could get it smoother though



The texture is a non-issue though, because of the next part: Al's Spray-on Bedliner

This is a 3-part polyurethane bedliner, that is fully tintable. On the left of the pic is a small bottle of surface prep, plus a bottle of my color tint: black


I recommend some kind of respirator, this stuff is wicked! (im not joking)


...and holy crap its done!



This part goes FAST. They claim the kit, after mixing, has to sprayed within 20 minutes or it will start to cure in the gun. Well no worries there, moving along at a decent pace you can spray an entire kit in ~10 minutes The whole underside took 2 kits, glad I bought an extra one when I ordered em.

I sprayed the whole underside, up into the wheel wells and all under-body xmembers, and halfway up the firewall as well


..and the money shot: This stuff looks (and feels) exactly like rhino or Line-X



I am super impressed with it, I think its going to work awesome. Its ~$85 per kit on Amazon, so it cost me ~$170 to spray the underside. Im going to order 3 kits for when I spray the interior just to make sure I can get it as thick as I want it. So it works out to about half what the local Rhino/Line-X dealers charge


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post #24 of 180 (permalink) Old 10-23-2016, 01:36 PM Thread Starter
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So with that done, I moved back over to my bronco. The time has come, for her to shed her sheetmetal once more. I decided to snap a few pics in the yard since this'll be the last time she ever looks like this!
















Ok, documented, now it 's time for the sawzall
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post #25 of 180 (permalink) Old 10-23-2016, 01:45 PM Thread Starter
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So that gets us to about a week or so ago, when I started dismantling it.

All glass removed


Top gone!


My new convertible


Still runs at this point; drove it intot he garage for the night


Next day, Bed is gone:

Saving this part


Bed off




Day 3, started stripping the front-end






Here's a good reason to cage your truck: The cab corners twisted enough I couldn't get to the seatbelt bolts


...and finally!


Stripped down to basically nothing at this point



This catches us up to today. Tomorrow I begin loading up the truck as I have a mountain of steel to scrap from cutting up both trucks. I painstakingly removed the harness from both so I can reuse them, along with a bunch of other parts, which made the disassembly take about a week, altho its obviously all done now. So the plan for this week is to dump all the scrap steel, and then just get the frame clean. Then I have a few things I have to do, before dropping the new tub on the frame. Getting ever closer now!


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post #26 of 180 (permalink) Old 10-23-2016, 04:08 PM
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post #27 of 180 (permalink) Old 10-23-2016, 06:32 PM
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You are moving right along with that, looking good so far. I just have one question, how did you put the body on its side without damaging anything .


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post #28 of 180 (permalink) Old 10-24-2016, 04:37 AM Thread Starter
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The cab was pretty well stripped; no dash, column, harness, seats, even the heater box was out. So that piece leftover was only maybe 100ish lbs. I pretty much just grabbed the rocker, lifted and just flipped it right off the frame.
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post #29 of 180 (permalink) Old 10-24-2016, 09:33 AM
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I was talking about the "new" bronco tube sitting on its side.


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post #30 of 180 (permalink) Old 10-24-2016, 02:22 PM
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Did you move? I don't remember that garage.

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post #31 of 180 (permalink) Old 10-24-2016, 03:55 PM Thread Starter
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Jim: oh yeah, duh, that one 5 coworkers and beer We did slightly bend the bottom of the rear fender, but im cutting that portion off so it doesnt matter.

Steve: Two years ago now, altho we finally sold the old house this past May This place is just over the mountain from the old house.




So I got everything loaded. Took two trips to the scrap yard as I just could not get everything to fit in the bed. Totalled out to 2,280lbs, for a whopping $45.60. That works out to .02/pound
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post #32 of 180 (permalink) Old 10-24-2016, 04:05 PM
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damn man. barely paid for the gas to haul the scrap.
no wonder my neighbor's property is over-flowing with scrap.
at those prices, it's barely worth cutting it up and hauling it off.
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post #33 of 180 (permalink) Old 10-25-2016, 07:12 AM Thread Starter
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Yeah over the last couple of years the Chinese have been flooding the market with steel, which has caused the price to drop and drop until it is what you see now. Thankfully the scrap yard is only 12 minutes away, so not too much fuel burnt. After that plus a stop at the bottle shop for a 6-pack, ive pretty much broke even
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post #34 of 180 (permalink) Old 10-26-2016, 01:46 PM
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Originally Posted by reptillikus View Post

So I got everything loaded. Took two trips to the scrap yard as I just could not get everything to fit in the bed. Totalled out to 2,280lbs, for a whopping $45.60. That works out to .02/pound
What the heck??? I really would think scrap would be worth more than this!

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post #35 of 180 (permalink) Old 10-30-2016, 03:41 PM Thread Starter
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Nope, it sucks. That price is for 'light iron', heavy iron & cast iron are more, but not much more. That said, if you know a scrap steel supplier (I do), you can get steel pretty cheap. I bought a piece of 1/4 wall 5*7 box tube for a future bumper project for pretty cheap. So it works both ways.



So the other day I power-washed the frame. Took the opportunity to hit the hard top too, it was pretty bad from all those years in the woods


Better now, but will still need work when the time comes.


Frame back in the garage, ready for more disassembly


This is the x-member I built to put the p/u cab on, in process of removal in this pic. Tomorrow ill bolt the factory body mount brackets back onto the frame, that I salvaged from the parts truck frame.


Also not pictured: I removed all cables for the rear mount batteries, and all the OBA plumbing. Chopped off more of the exhaust. Removed the rear bumper & dropped the tank, planning on a new poly one once i get further along. I removed the brackets on the frame for the stepside bed (still installed in the previous pic), and I removed the rest of the front bumper which was still welded to the frame. Now im back to a 'stock' frame to work off of, for bumpers front & rear (coming much later on).


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post #36 of 180 (permalink) Old 11-11-2016, 09:28 AM Thread Starter
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An update!

B-pillar body mounts reinstalled


Some rust repair on the frame.








had to do both sides



The frame had a small tweak in it, from trimming it for the p/u tank. Not too bad, after 1o years! But I figured nows the time to do something about it






Then I went back, and added a lip the the notch to strengthen it, as well as weld everything together


Chopped off all the crap ive welded to my frame horns over the years



Next project on the list, fix trans leak.

Drop frame to wheel dollys


pull out doubler



Fix leak, put back in.

Then yesterday I pushed it out on the dollys into the driveway to wirewheel & rattle can the frame. While the paint was drying I built this, so I could use the come-along to winch it back in


Today im gonna install my new poly gas tank, then make leads up for my winch, so I can use that next time I need to winch the truck into the garage

I have a poly body mount kit sitting in the garage, and new body mount hardware should be showing up today. So, weather permitting, the tub goes on the frame this Tuesday After that I need to take down the big tent, and then im taking a week or two off on this project to get some stuff done in the house and around the yard.
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post #37 of 180 (permalink) Old 11-11-2016, 09:46 AM
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Very cool stuff!
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post #38 of 180 (permalink) Old 11-11-2016, 07:55 PM
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What happened to the super slow part of this build. Looks like your moving right along.


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post #39 of 180 (permalink) Old 11-13-2016, 05:23 PM Thread Starter
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This is all the easy stuff. The slow stuff will come once I start working on the body work. Plus lots of redesigning the bumpers, a whole new OBA system, lots of rewiring, roll cage, etc.

I have been pushing pretty hard to get to this point, because I need the tent down before it gets cold enough for snow; my pace will definitely slow up a bit once that comes down (hopefully Wednesday).


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post #40 of 180 (permalink) Old 11-22-2016, 11:25 AM Thread Starter
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So last weeka bunch of buddies came by, and we got the body on the frame!



So awesome to see it in the garage, looking like a bronco again


Friday I got the windshield out, which revealed what appears to bea completely rust free windshield frame


For now, this is where I pause. Diesel needs the rear tank replaced & maybe a glow plug relay. The leaves are falling, and ive got painting to do in the house. So ill come back to the bronco in December.



Unfortunately on Friday, someone was thoughtful enough to hit my F250


So now im on the hunt for a new bed. Most likely just going to massage this one and leave it for the winter, then replace it in the spring.
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