Rept's Super Slow Re-Re-Rebuild (90) - Ford Bronco Forum
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post #1 of 192 (permalink) Old 08-02-2016, 08:42 AM Thread Starter
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Rept's Super Slow Re-Re-Rebuild (90)

Ok peeps, here we go again

So after years of wheeling and not caring, ive pretty well thrashed the body on my bronco.




The whole cab is twisted so the full doors don't come even close to closing so we have to use the half doors any time we take the truck out, and then tarp it up so it doesn't get wet inside n the rain/snow.
So after going back and forth, we decided to go back to a bronco body on this thing. The cab/bed was cool and all, but it dosent really have much room for carrying much gear, and not being able to drive it on the road sucks. So I stared looking for a bronco project. I wanted to stay true to the trucks roots (I have owned it 16 years afterall) which meant the body has to be an 87-91. I wanted to find something clean because im not a sheetmetal guy, and the condition of the drivetrain was completely irrelevant because im just going to drop the body on my frame when im done.

So I snooped around CL for quite some time. Seen trucks come and go, but nothing really jumped out at me. Then one day I spotted a lift 4-door bronco on CL up in the Poconos. Only two pics of the exterior, but it looked like a decent buy for the price, so I made the trip. On an impulse i decided to go up there and see if it would be a decent beater to cruise around in. Unfortunately it was a bit rough around the edges, more-so than I would've liked for a street cruiser so I decded to pass on it. But while BSing with the guy, he told me about this bronco he had planned to restore, but it never really happened. So we go over to take a look at it, and its perfect. its a '90 in decent shape with no motor or trans. The perfect donor vehicle! So we struck up a deal, and I brought it home


So here she is, in all her glory.




It was a parked in stones under a tree for 10 years, so while being absolutely covered in moss, appeared to be in decent shape!

He had put a body lift in it (homemade, about 2"), and he built his own shackle flip for the rear with some extra leafs stuffed in there for some more lift. And there it sat, never got around to lifting the front, or doing anything else to it.
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post #2 of 192 (permalink) Old 08-02-2016, 08:47 AM Thread Starter
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That was back in May, it pretty much just sat in the stones at my house until closer to the 4th of July, whena buddy came over to help me get this project started.

We scrubbed the hell out of the hard top (it still needs a lot more work) and then yanked it off and set it on the trailer. Then gave this thing its first bath in 10+years



Pulled the tailgate off; the shell is shot but the hardware is all in great shape. Started yanking out the interior and found an old mouse-house behind the real panel, along with the former tenant


We pretty much gutted the whole interior except for the dash, and then then called it quits for the day.
So much clean sheetmetal!


...and stuffed into the garage until the next time I could get around to working on it
.
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post #3 of 192 (permalink) Old 08-02-2016, 08:55 AM Thread Starter
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More disassembly progress!

The last of the interior & dash came out





Rust hole up near parking brake pedal


and a little bit of rust back near the tailgate


...That's actually the worst of it The rear fenders have some rot, but it doesn't matter since I have to cut the fenders to clear the 42s anyway. That will all come way later on.


This part is concerning though


He welded a piece of box tubing into the body out back instead of using body lift pucks, so im gonna have to get this cut out and see whats going on behind it. Don't want the body lift, the truck is tall enough as it is.

I also got the sound deadener stripped off the floor as well
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post #4 of 192 (permalink) Old 08-02-2016, 08:59 AM Thread Starter
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Fast forward to about two weeks ago.

Doors are now off


And I stripped and removed the front clip





The is no real rot on the under-side of the tub, but there is rust at all the seams in the sheetmetal. So after going back and forth I said screw it and set up the tent in the stones
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post #5 of 192 (permalink) Old 08-02-2016, 09:07 AM Thread Starter
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So last Thursday a bunch of buddies came by, we rolled the truck over to the tent, lifted the body off and got it set up.




The frame is back in the garage for now. Im stealing some brackets off it, plus all the body mount hardware, and then chopping it up for scrap.



So yesterday morning after I got home from work I suited up, grabbed the whire wheel & the sand blaster and went at it!




...so that's where she sits as of now. Before you ask, im not sand blasting the entire tub, only the underside. I have no intention on driving this thing in the road salt, but i dont want to get it all done and have the floorpan start rusting away a year or two later. The fenders & interior are clean with good paint on them, so theyre just going to get prepped and painted later on. The underside is going to get sprayed as soon as im done down there, so I can get it on my frame and get it back in the garage.

Progress on this thing is pretty slow as I only work on it a couple days a week. Today im painting in the house, but hopefully tomorrow I can get back out there and do some more blasting.


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post #6 of 192 (permalink) Old 08-02-2016, 11:06 AM
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Good to see you working on it Kevin.

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post #7 of 192 (permalink) Old 08-03-2016, 12:51 PM
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post #8 of 192 (permalink) Old 08-03-2016, 01:21 PM
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so... are you gonna keep it nice now or go back out and scrub trees again?

sub'd
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post #9 of 192 (permalink) Old 08-03-2016, 10:14 PM
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Awesome to see it becoming a bronco again, even though I dig the pick up version.


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post #10 of 192 (permalink) Old 08-03-2016, 10:35 PM
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Quote:
Originally Posted by BikerPepe` View Post
so... are you gonna keep it nice now or go back out and scrub trees again?

sub'd
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post #11 of 192 (permalink) Old 08-03-2016, 11:10 PM
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Am I the only one who can't see the pictures? Good to hear you are going to redo it again.


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post #12 of 192 (permalink) Old 08-04-2016, 12:44 AM
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post #13 of 192 (permalink) Old 08-04-2016, 01:19 AM
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It must have been blocked by the Internet at work. Looks like its gonna be pretty cool.
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post #14 of 192 (permalink) Old 08-04-2016, 05:58 AM
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Definitely sub'd. It'll be sweet to see it look nice again.

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post #15 of 192 (permalink) Old 08-04-2016, 08:43 AM
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After seeing the body that's getting replaced, I'm pouring a preemptive 40 oz. for the new body.

And subbed!
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post #16 of 192 (permalink) Old 08-04-2016, 09:19 AM Thread Starter
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Thanks guys

The plan this time, is to make it look good. I aready bought a set of 80-86 Bushwacker Cut Out flares in prep for attempting to cover the tires a little bit. I intend to properly cut the wheel wells though, not just sawzall em open like they suggest. New bumpers are in the works as well, since mine have been mostly the same (just minor mods here and there) for over 10 years. I have a mostly complete set of interior parts in Charcoal (the dark gray) that's going in in place of the blue. Gonna spray the interior in Al's Liner, as well as the underside. Thinking about a gun metal color for the exterior, and im definitely going to put the racing stripes & depth markings back on as a throwback to the p/u body. Also going to revisit the wiring for all the stuff ive added to the truck (OBA, ARB, elec fan, line lock, etc), and give that an update as well, since ive definitely gotten better at wiring in the 10 years since Ive added all that stuff.

End result *should* be a really nice bronco to cruise around in, with my proven one-ton drivetrain underneath. Yeah im thinking of taking it a bit easier on the trails; with the p/u cab, since I wrecked it the very first day offroad I really didn't care too much what happened to it, but this time I kinda want a clean rig.


I have yet to start stripping down the bronco. I need to finish blasting the underside of the donor body then get it painted underneath. Then I need to chop up the donor truck's frame, and then im going to dismantle the bronco. Plan is to be able to just strip it down and roll the frame into the garage. Then I need to do some maintenance to it as sitting idle for months at a time as wreaked havoc on all the seals; it needs a rear pinion seal, rear wheel seals, front diff seals, O-rings in the ARB and a front pump seal for the trans. Also need to repair one body mount hole, and chop off the mounts I built for the stepside bed. THEN the donor body can go on my frame So yeah, lots of work to do, before I can even set it in place.


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post #17 of 192 (permalink) Old 08-04-2016, 07:35 PM
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Looks like a well thought out plan to bring your rig fully back to Bronco status.
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post #18 of 192 (permalink) Old 08-04-2016, 09:17 PM
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Rept's Super Slow Re-Re-Rebuild

If I can cruise around Rausch and keep mine somewhat clean, (last trip added A LOT of pinstripes, not the cool kind) you shouldn't have issues.

BTW, your still ahead of me, my axle has been sitting for a few month and I have about an hour worth of work and it would be ready.


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post #19 of 192 (permalink) Old 08-05-2016, 10:11 AM Thread Starter
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Dammit Jim stop slacking and get to turning some wrenches!

Quote:
Originally Posted by bigzirb View Post
Looks like a well thought out plan to bring your rig fully back to Bronco status.
Yeah this has been coming for a while, so ive been going over all the little things I want to do while its apart. This list is not short! Theres lots of other things I want to revisit while im in there. Im even thinking of moving the air compressor down to where the smog pump was, so I can put the factory air box back in. As an added bonus, this would allow me to go full baller and the get the a/c working again



As for updates...there isn't really one Progress has been made! But im still sand blasting, so not much.


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post #20 of 192 (permalink) Old 08-05-2016, 11:27 AM
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Originally Posted by reptillikus View Post
Dammit Jim stop slacking and get to turning some wrenches!

It's hard when you turn wrenches all in the summer in a hot shop, last thing I want to do is more of that when I get home. Back at it soon though.
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