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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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Discussion Starter · #681 ·
We got it silenced or silent...


How?
With ugly welding and such

37EEEB16-DB06-4036-87C7-DCFA39420901.jpeg
It’s already removed,
:)
Another point crossed off

will get the axle shock brackets re-welded on Thursday, weight taken on Wednesday
Then I only need the dyno sheet (either Friday or early next week), then we should be set!!
 

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78 Custom 460 NP435 NP205 Sniper EFI HyperSpark Ignition 4.56 Gears Front/Rear Grizzly Lockers
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It looks like a water faucet.
 

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That’s different.
 
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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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1,144 Posts
Discussion Starter · #685 ·
I hear your thinking, its ugly, agreed, it was a silencer for the video.

i ripped it off immediately afterwards...

further I plan to cut if off that the red line mark on the picture, straight in line with the pipe coming to the elbow.

179357





but hey, look, I took my wifes daughter and we did some small mini wheeling, she was totally annoyed, as she thought we will drive on normal paved road instead uphill... ;-)

do not listen to the tow device hitting ground, with the 35's it will be better, I hope!

 

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Awesome I like it.
 
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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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1,144 Posts
Discussion Starter · #687 ·
Had a day off on Wednesday.

went to the scale in the morning and then when to a supermarket - parked next to normal Asian SUV - oh boy, they all were annoyed and scared partly...
Great!
Scale said 2360 kgs - close to 5303 lbs with around half tank of gas.

I had to queue quite long and the engine went hot... will need better fans - later!

then I made this wheel Wednesday and cleaned the last 2 rims with polish stuff and such, not perfect but good enough for some home made job!

AEEC01E9-6116-4B09-BB90-8CE709030BFF.jpeg AB8FD0E7-602D-4B79-9B97-5B1B01F1E2F7.jpeg

Last one to go...
D401BDFE-5E8F-4A57-B92B-2D45BFBC39D0.jpeg

ACBC0415-8BC5-4AB6-B07F-84F7C2A5755A.jpeg

we will be out today with the Bronco and the dogs, will take some pictures to share!!

cya all later the day!
 

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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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1,144 Posts
Discussion Starter · #688 ·
Funny day
First new hobby
1805FEA3-BE12-4BF6-9973-98794C5143C4.jpeg It used 43 liters for 95 miles, that’s around 27,7 liters per 100km
I expected 25-30 for sure. Plus I mostly did not drive longer distances, it idled a lot at the certification etc etc.

When I came home, the horn was not working, I took of steering wheel to find a cable sheared of the plate giving contact, put it all off and soldered again, time of strong horns is back :) neighbors surely liked it on the local holiday

at the same time I let my wire repaint the shift indicator, which was simply not existing before, still gotta change the upper column bearing, but I may want to install an industrial ball bearing if possible instead of the old style bearing

6093ED11-8FFD-4ADC-9C68-87B4799F66F0.jpeg
Anyhow, this turned out great!!

A695818D-8C29-4FF5-9532-39F002FA7525.jpeg After that unplanned wrenching sessionI took family out for a walk, even rain was approaching. Was fun! Holley enjoyed it

3F99535D-0BB6-4CE3-81BC-3423FF1C4885.jpeg
More dogs needed
EE96A81E-0043-4510-B2E3-3F3A5E0ECC76.jpeg

Now I gotta eat cake and start with some cold snacking!!
Cheers, have a great day!
 

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Looking forward to seeing the trim added to the rear taillights
 
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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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1,144 Posts
Discussion Starter · #690 ·
Looking forward to seeing the trim added to the rear taillights
pretty soon, but first gotta sort the dents on the left, as this goes down into the edge above the taillights :)

Here guys, its a daily now, :)
went to work with it!!

179500
 

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pretty soon, but first gotta sort the dents on the left, as this goes down into the edge above the taillights :)

Here guys, its a daily now, :)
went to work with it!!

View attachment 179500
Ha, a bit scared to ask you how much gas is right now in Germany ;) but truck looks good, you get all the registration stuff solved?


Sent from my iPhone using Tapatalk
 

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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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Discussion Starter · #692 ·
Ha, a bit scared to ask you how much gas is right now in Germany ;) but truck looks good, you get all the registration stuff solved?


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well, I paid 1,56€/1 Liter yesterday, thats increased a bit, but fuel is generally nearly double price compared to US.

1 gallon is 3,78 liters
1 Euro is 1,207 USD so:

1 gallon = 5,89euros, or 7,109 USD.... and if we say the bronco needs 27,5 liters per 100 km this is 42,90euro/100 km.... crazy, if I compare that to my hybrid e class, which takes 5-7 liter diesel and some power from the battery.
 

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well, I paid 1,56€/1 Liter yesterday, thats increased a bit, but fuel is generally nearly double price compared to US.

1 gallon is 3,78 liters
1 Euro is 1,207 USD so:

1 gallon = 5,89euros, or 7,109 USD.... and if we say the bronco needs 27,5 liters per 100 km this is 42,90euro/100 km.... crazy, if I compare that to my hybrid e class, which takes 5-7 liter diesel and some power from the battery.
7,09 a gallon?? Wtf man we're paying 2,26 a gallon here and I think thats ridiculously high... Might want to look into making it a hybrid! Haha


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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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1,144 Posts
Discussion Starter · #694 ·
Yep, it’s freaking expensive here.

got my welder since yesterday and it’s doing WAY WAY better that the old unit in our shop at work.
We redid the lower shock mounts at rear axle and the exhaust at some spots...

9D86832A-5C48-4079-BF53-1CB676036FD0.jpeg


3EB81313-BE3D-414B-BD91-C45B9E8F352D.jpeg

After - then hit it with black rattle can..
BB6D4110-565F-44CE-9EEF-F56086EF6505.jpeg

at the moment its raining cats and dogs and probably cows later, so debating if we shall switch out the oil pan gasket vs a felpro to stop that leak at the front.

the dip stick from the Ford Motorsport pan does not seal, I need the clip.
Anyone has a spare??
 

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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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Discussion Starter · #695 ·
Hey Guys and Gals

small update from the weekend, I did not do a lot, as I did not have too much material for wrenching and the weather was pretty ugly.

after I welded the lower rear shock mounts and painted it black again, I took part of the exhaust apart where lots of holes where in from first 2 welding approaches.
With the new welder I would spot weld and rope weld it a bit better and grinded it down, painted it with high zinc paint, so that its somehow protected.
did not take pictures, but its looking way better than before.
Next exhaust task will be to build a new pipe to muffler on driver side, so that both exhausts are mostly equal lenghts, instead of routing driver side header over to passenger side and back to driver side. Don't like this.

Then it was time to seal engine oil pan... oh boy.
as the exhaust was partly off, it was easy access after the starter was taken off.
Look into the pan, not really happy to see a seal applied like this. I mean its a metal rubber hybrid seal, (metal on the flat areas in between the rubber) so looks to me as a kind of expensive good quality seal.
I had a blue Felpro seal which is in now, and that the 4 half moon corners I applied some high temp RTV, but nowhere else.
That old seal was put in with RTV all around, not sure but this does not sound correct to me.

379.jpg 380.jpg

Last but not least I grinded down the big D44 cover I got instead of the stock one, as the sway bar is grinding on the cover front where the label is placed.

Here, remarked it on an old picture.... basically not willing to take away the sway bar. (due to onroad drivability)

179650

in the end oil was put back into the engine and I let it warm up to 90 degree celsius coolant, so oil nowhere from the oil pan, front is sealed now, rear oil seems to come from move up on the rear side of engine.
As oil sender is dry, the only thing that could leak is intake manifold to valley pan.
If that's leaking though, then every seal that could leak was leaking on the rebuild engine, not really happy.

valve covers, both, seal was destroyed (too much claming force of screws applied)
Sump seal, see above, now intake manifold rear....
 

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Charlie don't surf..
'92 Ford Bronco XLT
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It's disappointing seeing that..Really no excuse to mess up seals when rebuilding an engine, especially the oil pan. If they're not paying attention to detail with little stuff like that, I'd wonder how good of a job they did on the internals. Unfortunately, you have no way to know..

At least you have most of it sorted and can get out and enjoy it a bit..That's the most important part..
 

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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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Discussion Starter · #697 ·
just agree 100% to what you write, I do hope they at least build it mechanically correct.

I was not told that if the top bolt of the passenger side connection engine / transmission shall be set with thread sealer, otherwise a leak might come from there, will take the bolt out later and see if its wet, if not, its not coming from there.

unfortunate you not see anything from the backside of the engine without cutting the firewall away ...
 

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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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Discussion Starter · #698 ·
so, updates on a monday.

quick one: got my next 5 day plates this morning, so I can put the car on a scale this week :)

then I promised pictures of the dents:

passenger side: --> this area is really awfull, hope it can be repaired
View attachment 179303

driver rear: not nice as well, but potentially it can be pulled to some extend and the smothened out with some bondo.....
View attachment 179304
179866


Remember these 2 buddies??

Lets talk about the "left" :)

I got some hours free this morning, after my travel to Czech rest of the week, and went along with some hammers, heat gun and some stuff to ply or pry?

well, look how far I got on the driver side. not too bad if I re-cap that I am no body shop guy and basically never learned this in any kind...

the tailgate was hitting the inner side of the corner slightly, even I did not take a picture of it.

so, here is after the first 45 minute session with several hammers and heat to it.... the gap to the tailgate went nearly perfect.... astonishing, you hit it with a hammer somewhere else and it straightens out for some part....

381.jpg 382.jpg

then I sanded it mostly to bare metal, to verify where still low spots were in, hammered a bit more and then primed it.

383.jpg 384.jpg

I will sand it down again and then put very thin bondo on it and sand it again.

Then prime it again and paint with a rattle can in wimbledon white... so then I have at least covered this corner and tomorrow I may try the other side.
 

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Charlie don't surf..
'92 Ford Bronco XLT
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Nice work..that came out really good..I know how difficult it is..should have you come fix mine..It was a lot worse..

had to cut and weld metal back in...not pretty but got the job done..
1621602346293.png 1621602395432.png 1621602567410.png 1621602591988.png
 

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1979 Bronco Ranger XLT, 400m engine, C6 trans, D44 front with Dick Cepek manual hubs
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Discussion Starter · #700 ·
Nice work..that came out really good..I know how difficult it is..should have you come fix mine..It was a lot worse..

had to cut and weld metal back in...not pretty but got the job done..
View attachment 179869 View attachment 179870 View attachment 179873 View attachment 179874
oh boy, that was a tough job.
Well done and not a lot of Bondo needed, well professional!!

i had to weld the other side as well, but metal was pretty thin, so even I put induction of welder very low, but still created holes...

the driver side got 3 thin layers of bondo, whereas the last one is ready to be sanded today. Then this can be primed and painted.

passenger side did not work out nice, there are big dents around upper tire carrier mount, this need to be pulled with welding and slide hammer, but I do not have the equipment, so I concentrate on the cut and get this done.

here‘s some interim status of it

before
08FE0031-CBCF-4AD0-825D-084631FAA04F.jpeg 6BDB0403-9920-48D9-82F3-AA836FB44DA9.jpeg
D3E3B49D-6EC9-4928-8767-754CD78E9C82.jpeg

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EBB0F2B6-21C7-4740-A7B2-B75E11F6C80B.jpeg

blended my eyes badly :-( let’s see how today’s go or not.
One of the lower tire carrier bolts snapped off, gotta weld a nut one it... maybe not today :)
 
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