Rept's Super Slow Re-Re-Rebuild (90) - Page 5 - Ford Bronco Forum
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post #81 of 189 (permalink) Old 04-07-2018, 10:26 PM
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Thanks for sharing the detailed steps in the fender cutouts. I wondered how much needed to be cut off to install those. Nice build!
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post #82 of 189 (permalink) Old 04-15-2018, 04:40 PM Thread Starter
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Its been a while, so i thought id update.

Progress is slow.

I put the hood back on, and roughly aligned the front clip, so i could start on the fender liners. Needed to make sure everything was straight before i started cutting into stuff!

I abandoned reusing the original fender liners, as they would require too much work, and put the homebrew sheetmetal brake to work.

Youll note the wheel well is open pretty much right to the battery tray. So the tray will end up being part of the new fender liner.


First thing i did was to make this piece. It bolts to the battery tray, and the firewall. The oddly shaped cutouts are to clear the shock & coil towers.


Next up is this piece. This keys into the battery tray as well.


Here's the rough idea:




I whipped up a third piece, that boxes in the heater box.


That gets us to here. Still a lot of gaps to close, but progress is progress.


Pulled it all out, and started tacking it together




...And where im at today.


This has been a constant evolution. Every time i pull the panels out i make subtle changes to get them to fit better, and there are more changes coming yet. I need to fill in a lot more gaps, and im hoping that when done i wont need that 1x1/8" brace because its a PITA to install. Currently i think ive got 7 more pieces i need to make, to close it all in.

I bought a ton of stainless hardware from Bolt Depot, some of which im using now, and the rest of the hardware is just temp stuff to hold it all together. But the goal is to have one big removable panel, for easy access into the engine bay. Hopefully i can get it to work


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post #83 of 189 (permalink) Old 04-15-2018, 11:59 PM
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post #84 of 189 (permalink) Old 04-16-2018, 10:55 AM
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Killer fab work, you make it look like anyone can do it.
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post #85 of 189 (permalink) Old 04-16-2018, 01:35 PM Thread Starter
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Thanks Believe me when i say im winging it. I know just enough to get myself into trouble
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post #86 of 189 (permalink) Old 04-16-2018, 04:34 PM
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Kinda sucks you can't do something with the heater box so the wheel well would hang lower that the opening, looks good though.


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post #87 of 189 (permalink) Old 04-17-2018, 10:05 AM Thread Starter
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Yeah the heater box sticks out pretty far, even the non-a/c box. As i recall the OEM fender liner has a small bulge in it to clear the box. Fortunately the tires get nowhere near close to the box. Once i get it all finished and paint the fender liner black you wont really notice it. The p/u cab had a similar box built around the heater box; it wasnt too noticeable once done.





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post #88 of 189 (permalink) Old 04-26-2018, 09:28 PM
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Looking forward to seeing how these turn out as I have similar plans when I cut my fenders.

Slow or not, at least you're still updating this thread, I've seen too many good threads die 3/4 of the way done on many different forums. Glad to see this isn't one of them.
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post #89 of 189 (permalink) Old 04-28-2018, 10:44 AM Thread Starter
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Yup, still trying to make progress, slow as it might be. Ive owned this truck just about 18 years, i cant give up on it now. Altho currently as i type this i have a little guy climbing all over me trying to get to the mouse and keyboard


Now that the weather has warmed up ive moved into the laundry room. Found all sorts of issues with the PO's renovations, so its currently gutted so i can re-do everything. So thats is consuming most of my time. However, some progress has been made

The current state of the fender liner:



...and installed




With the flare installed, you can barely tell ive done anything


I figure once the liner is done and painted black, you wont even notice ive done anything, which is my goal
I still have what i think will be 4 more pieces to make, and then this side will be done.
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post #90 of 189 (permalink) Old 05-15-2018, 07:52 PM
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Loving this! Can I ask what size sheet metal you have been using and where you got it?

I'm in the process of squirrelling away parts for my rusty rust rust project

The project will include a lot of sheet metal haha

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post #91 of 189 (permalink) Old 05-16-2018, 09:02 AM Thread Starter
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Thanks! Ive been using a 24*36" sheet from Lowes. 4*8' sheets from the local steel supplier would be a better buy, but theyre a hassle to handle and cut, esp when im making such small pieces. Its only 26ga. Fairly thin, but fine for what im doing. Basically just trying to keep mud out of the engine bay. Thus far everything ive cut has come out of one piece. Its goes pretty far if you plan your cuts out.

Im using 20ga for the floor repairs, altho those are pretty minor in my case.
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post #92 of 189 (permalink) Old 06-21-2018, 03:44 PM Thread Starter
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What is this, updates on two vehicles in the same month?!


Finished the passenger side fender liner:






Closed off the hole for the body mount, and made a small panel to fit between fender & firewall to keep door hinges cleaner


Moved to the back, and cut some more sheet metal off the rear wheel well






Then painfully pushed the truck over a couple feet towards the center of the garage, and cut the rear left:


Both need some final feathering to clean up the endges, but thats the final shape. Obviously need to finish trimming the bottom corner, but im not going to do that until i get a new tailgate and see where i want to cut to.

Then moved to the front left, and started bending up more sheetmetal!




Lots of room under the hood still:


small panel to close in the corner






And the finished liner:






This side definitely went a lot faster than the other did, now that i had a rough idea of what i wanted to do. For now im calling them done; i might go back way later and add pieces here or there, but i think this is gonna work pretty good. Hopefully next week i can rip it all back out, and begin priming & painting all the pieces. I also want to yank the front clip, so i can paint the inside of the fenders black, along with the section of firewall thats still white. Then i can put it all back together and move on to the floor pan


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post #93 of 189 (permalink) Old 07-12-2018, 11:01 PM
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Really impressive work.
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post #94 of 189 (permalink) Old 07-13-2018, 08:42 AM
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@reptillikus those look great..exactly what I need for my rig..wanna build another set??

you need a separate thread just to cover the fab on those inner fender liners..

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post #95 of 189 (permalink) Old 07-14-2018, 01:27 AM
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Iím jeleouse, you da man. Maybe someday Iíll have a shop, nice setup.
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post #96 of 189 (permalink) Old 07-15-2018, 09:06 AM Thread Starter
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Thanks guys

Honestly was just winging it the whole time
Carboard templates, some careful measurements, and then fit & removed each fender liner about 100 times to trim until it fit properly I learned from the 1st time i did it, to cut everything a hair oversize and trim to fit. I actually did pretty good i thought, i only messed up one panel, and was able to recycle that one into smaller pieces used elsewhere, so basically no scrap

No way i couldve done it w/o that homebrew sheetmetal brake. Its not perfect, but it worked great for this job.



Dunno if you guys saw, but a couple weeks ago i picked up these bad boys:





Theyre used, but as you can see, they have damn near full tread.





They make 35s look like 235s


Absolutely massive tires, they even make my 42s look small!





Ive got a set of H1 wheels i recentered some time ago but never used; theyre at a buddies shop waiting to be powdercoated. So at some point down the road ill get them mounted up and swapped on, no real rush there. Very soon here ill be putting the bronco back on wheel dollys so i can start doing proper body work, rust repair, bondo/sanding, etc so theres no real need to get these mounted up for quite some time yet.
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post #97 of 189 (permalink) Old 07-15-2018, 09:18 AM Thread Starter
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Quote:
Originally Posted by jermil01 View Post
@reptillikus those look great..exactly what I need for my rig..wanna build another set??

you need a separate thread just to cover the fab on those inner fender liners..
Ha, thanks

Truthfully, the liners were all trial & error; i had a big cardboard template and cut oversize, then once the piece was made i fit it, marked it with a sharpie and trimmed it over and over and over until it fit. it took a lot of time, but it was better than making one mistake and costing me an entire sheet of steel to re-do it. All the bends were made ont he home-brew bender, and actually all my cuts were made using .045" cutting wheels on my angle grinder. So again not the most efficient way to do it, but it got me some nice clean lines to work with.


If you want to drive up here, ill build a set of liners for yours

Quote:
Originally Posted by 445 FE Bronco View Post
I’m jeleouse, you da man. Maybe someday I’ll have a shop, nice setup.

Thanks Truthfully, the garage is nothing special, just a plain old two-car garage. 8' doors so i had to put wheel dollys under the rotors to get the bronco low enough to go thru the garage door It fit with 1" to spare, so i cant add any more lift to the suspension or it wouldnt go back out the door. Whats nice is its 100% a workshop, as we both park our cars outside. But that allowed me to pretty much line the walls with shelves, cabinets, steel, etc. Considering the last time i did a body swap it was in the backyard at my old house, this is pretty awesome


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post #98 of 189 (permalink) Old 07-15-2018, 07:52 PM
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Cool build thread!
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post #99 of 189 (permalink) Old 01-22-2019, 09:53 AM Thread Starter
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Oh snap


With the diesel and the green bronco 'done', its time to get back to this!

Fixed a hole in the rocker:


Thought i had a before pic. Just pretend it was rusty there


Moved inside. See the speckles on the roof?




its bedliner Apparently when i sprayed the underside, i didnt mask off the trans tunnel well enough, and i got overspray all over the roof and B-pillar. So i now have the majority of that removed from the paint.

I moved to the rear wheel wells. Since i cut them open, the inner wall was only partially there. I elected to remove the rest of it, since it holds dirt and therefore moisture






Both fenders done, no rust repair required, just need some more wire wheeling and some primer. They will get HNR/bed liner in the spring.

Moved back inside. i have two more spots to deal with and i think im done with rust repair:




Hopefully ill get out there tomorrow to start on those.

I still need to finish cutting the rear corners and thatll pretty much finish up the body work to the tub, but ill still need to sand/bondo everything.

I need to do something about my doors. They are in decent shape, except they both have one rust spot, right in the middle where the mirror bolts on




I am not confident in my ability to fix that, w/o it being super obvious. My bondo game is not strong! So im currently debating what to do. One door needs a new rivnut, and both need to be repaired there. Im gonna try to clean them up and see if i can fix the doors, as id rather not buy new ones. I already need a new tailgate as mine is rotted badly.

So, im rapidly approaching the part of this build where i need to start spending money! And i need to get the laundry room done so money will be split to both projects. So im guessing this will go slow for a bit.

So, i need input from those of you who have done this before.

Thiings to do:
  • fix rust
  • sand/bondo
  • paint!
  • bed-line interior
  • roll cage!
  • bumpers/sliders
  • electrical work

Electrical needs to be last because i need the interior in. I need to paint before i put the cage in, since its not staying white. And i cant bedline after the cage is in, unless im spraying over it, which i didnt want to do. So that means, i pretty much have to do it in the order above. my concern is with the amount of work left to do, if i should put off paint as long as possible. The only real variable is the bumpers/sliders, i suppose i could do those before i primer anything. This would mean finishing the rough body work, and jumping to the bumpers/sliders, then going back to body work. I guess it seems obvious when you type it out Thoughts??


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post #100 of 189 (permalink) Old 01-25-2019, 05:01 PM Thread Starter
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Rust cut out of rear driver corner, it was a bit worse than it looked!


New steel tacked in:


...and done! Good enough for the interior, its gonna get covered in bedliner anyway.


I also fixed the small hole on the passenger side.

From there i moved on to the rear corners.
This is a bumper i bought for a future project for the green bronco, i mocked it up on this one to see how it would fit and then never took it off. Considered using it on this one instead, but i have some ideas that would require modifying the bumper so ill probably just start from scratch. We'll see what happens when we get there.


I had started cutting the corners when i opened up the wheel wells, but never finished. Well, that time has come!


The typical cut everyone does


...both done, looks much better now!



So i think that unofficially finishes rust repair on the tub Im sure ill find more to fix when i start sanding & prepping for paint, but for now im moving on!


So i was talking to my brother, and i guess im going to try to fix my doors. Theyre both pretty clean, except for a patch right in the middle of each, where the mirrors attach. This is going to be a challenge for me, as all my repairs thus far have been in corners or at body lines which made them easy to hide. Its going to be tough for me to get these right, so you cant tell.

driver door:


passenger door:



Ill start on those next week. Once theyre done (or wrecked lol), im going to switch gears and start building bumpers!


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