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Discussion Starter · #1 ·
I want to thank everyone for this resource. I am trying to restore a 95 xl. Unfortunately, it's in worse shape than I realized, when I bought it, but I'm making progress. Currently, I'm working to patch a hole by the driver side rocker and then on to the rear cross sill.

I also purchased an 88 that I initially planned to use for parts. I am in the middle of the rust belt and somehow this one has survived with only owner inflicted damage. I had initially planned to use the quarter panels on the 95, but I have decided it would be better to fix than cannibalize. It does run but it does need a transmission. I will create a seperate post about it, as I have several options for replacing it.


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82 XLT Lariat 351w, Edelbrock 1406 4bbl ,C6 auto, auto locking hubs ,33x10.5x15
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Welcome to the forum. Looks like you have your hands full... Pretty sure there's a vendor on here that makes/sells rear sills. I saw a post last month about it... Might be worth a search.
 

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1986 Eddie Bauer 5.0EFI AOD Full length headers Y pipe into single 3" Magnaflow 3" factory exit
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AMD makes the rear crossmember, but other vendors carry it as well. Welcome by the way, its good to see another Bronco being saved.

I replaced my rear crossmember a few months ago & I can say, if it needs replacing, a lot more metal will too. Check out my build thread linked at the bottom of this post, I documented it pretty thoroughly to help others see how involved it is it should help you understand how ugly things get, once you lift the skirt up, but fear not, its not tough work to do, and very satisfying to see it built back into a sturdy truck! Rockers, quarters, structure, floors, all covered in my build thread, which is still going on, but nearing completion.

180344
 

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Yo Stitch's 95,
Welcome to our site! I'll look at your C6 post.
Here's the 1988 Ford Bronco & Truck Service Manuals by Larry J via Kingfish999 in Google Drive @ 1988 Ford Truck Service Manuals (Thank you Larry Jorgensen) - Google Drive

1988 Bronco Dealer Brochure @ https://www.broncocorral.com/resources/1988_ford_bronco_brochure.pdf

Haynes Red Manual for 80-95 Bronco & F Series @ Hanes guide 80-96 bko f series.pdf by BroncMom

For the 95, ASAP, find out if speed control recall work, if equipped was completed. If you still have concerns about Recalls, please contact the Ford Customer Relationship Center:
US: 800-392-3673 | CA: 800-565-3673
Note: 3673 spells "FORD" on phone keys
For the hearing- or speech-impaired: Please contact the Telecommunication Relay Service by dialing 71
"Summary: ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN. THIS COULD RESULT IN AN UNDERHOOD FIRE."

1995 Bronco Dealer Brochure @ 1995 Ford Bronco

1995 Bronco Drivetrain, Powertrain Service Manual - Google Drive
&
1995 Bronco Chassis, Service Manual - Google Drive
To switch between folder list & grid views, click the button to the right of the "DOWNLOAD ALL" button in the upper right corner of the window) by HawkDriver

For any Bronco questions or to chat about it's planned modifications or build, it's better to post each seperately in Noobie Bronco Tech Questions. Flame free zone. This will get more attention and you can build up your post count to get into other sections such as Bronco and Ford Parts/Accessories (50 posts required to participate due to scammers who preyed on our members).

See How to add your Signature @ Bronco Forum - Full Size Ford Bronco Forum by BigBlue 94

Forum FAQs includes for example, Hot to Use Search. How To Save (Bookmark) Threads Or Posts, How To Upload Images To Posts and more tips!

Baba Looey's Favorite FSB Links (lots and lots of tech links) including, "how do I get the tailgate glass to...", etc.

Find time to Participate and VOTE in our Full-Size of the Month (soon to change to Quarter) Contest and later in the year, Full-Size of the Year Contest @ Voting You will get ideas by those competing. Prizes are awarded to the winner; a full spread in Bronco Driver Magazine with a year's subscription once the article is submitted; and a year's worth of premium FSB membership!
Al
 

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Discussion Starter · #5 ·
I had initially planned to cut the cross sill out of the 88. When I bought it the seller was planning to part it out because he had messed up the title. It was is his name but it was going to take a few months to get an appointment to fix it. Fortunately, I was able to get it fixed through my dmv, with his help ofcourse.

Next, I did manage to find a cross sill in a local junk yard. Surprisingly, it's in decent shape. I think it has only been in the yard for a few months. It does have a couple of holes it in that need patched but the structure and shape are still there. I normally would not have gone that route but the price was so ridiculously low for the wheel tubs, quarters, and sill, that I cut them out just for the experience. As an added bonus, it also had a decent tailgate on it.

@Rob_64-365, I have been lurking and watching your build thread for a couple of months. It has been a great resource. I think mine is rusted in all of the same places as yours. Several of the spots under the carpet had been repaired at some point, but the PO didnt paint the patches. Needless to say they need fixed again. Like you, I'm just now learning to weld. I did get a similar welder to the one you are using, without the stick option.

I may still buy a new sill anyway. I'm trying to hold off making any big purchases untill I have the 88 running. I'd hate to buy all the missing parts for the 95, then find out that I cant fix the 88. I also have a complete, rust free, front clip from a 96 F150.


I decided to start with a spot in the driver side of the cab. I almost have it welded in but I'm having a little bit of trouble with the welds blowing through. I wasnt having that problem with my practice welds, but I'm gonna practice some more.


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Discussion Starter · #6 ·
@miesk5, thank you for those links, I will take at look at them.

The 95 doesnt have cruise control, so I may have dodged a bullet there.

I'll work on getting the info added to my signature.

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1986 Eddie Bauer 5.0EFI AOD Full length headers Y pipe into single 3" Magnaflow 3" factory exit
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Haha, looks framiliar!! Glad my thread is helping you out, as a first timer myself, I felt it was good to show others to just go for it, why not, we'll get it figured out, just like everything else!! Thin spots tend to blow thru easy, sometimes you just keep pushing till you get to good metal, & sometimes its easier to just make a little patch. The good news is, the sheet metal doesn't care, it's nice and strong when your done! Half the battle seems to be losing the fear of what to do.

Sounds like you'll have 2 Bronco's when your done!! What area of the country are you in?
 

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Discussion Starter · #8 ·
Haha, looks framiliar!! Glad my thread is helping you out, as a first timer myself, I felt it was good to show others to just go for it, why not, we'll get it figured out, just like everything else!! Thin spots tend to blow thru easy, sometimes you just keep pushing till you get to good metal, & sometimes its easier to just make a little patch. The good news is, the sheet metal doesn't care, it's nice and strong when your done! Half the battle seems to be losing the fear of what to do.

Sounds like you'll have 2 Bronco's when your done!! What area of the country are you in?
I'm in the southern part of West Virginia. Everything here is rusted out or very expensive.

My goal, at this point, is to get both of them going. I had hoped that the issue with the transmission was minor but I had it checked last week and the problem does appear internal. The PO told me that, so I wasn't surprised, just hopeful. Nonetheless, I will get it going one way or another. In this area, it's easier to buy donors than parts. As a result, I should have several transmissions, just not an exact fit. At this point, my biggest issue is procrastination and space.
 

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Discussion Starter · #9 ·
Well fixing the floor has been a challenge but I'm about there. I think I picked the worst place to start, considering I didn't know how to weld, but it's in there. The welds are not pretty but appear functional.

I still need to put a new track for the weatherstip. I'm optimistic that it wont be as tough.


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Discussion Starter · #11 ·
Thank you. I was lucky to find a truck at the junk yard to cut that piece out of.

The biggest lesson I learned here, is to keep the metal as tight as possible. Once I got the welder dialed in, every place I had a problem with blowouts, had a small gap in the metal. For those just learning, like me, file fit your patches. Make them as tight as you practically can. Don't just assume that you can fill the holes with weld. While you technically can, it is exponentially harder, and adds alot of work to the cleanup.



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Discussion Starter · #12 ·
I finally finished my floor pan and can move onto the rear sill.

I'm not really proud if the work, but considering the number if bends, and the fact that it's the first thing I have ever welded, I'm happy with it.


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Doesn't look terrible. You should start a build thread 👍
 

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I am planning on it, but I dont think I have enough posts yet to start one.

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Ah... Nope... Think you need like 5 or 10 more... Time to go thru the anything else section and get those posts 😉
 

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Yo Stitch's 95,
As BroncMom advised, Build Section requires 30 non- padded posts.
When you get to 30 posts, send me a message and I'll move tgread from Noobie section or from here,
 

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Discussion Starter · #17 ·
@miesk5 thank you. I thought that was what I had read, but I couldn't find it again.

Today, I spent my time repairing a rear cross sill. I bought this one out of a junk yard bronco. For the record, I would not reccomend anyone using a used cross sill, unless it's in immaculate shape. The work that went into rebuilding this was not worth the little money I saved. I bought this more for a learning experience than the part, and I got the entire back end of the bronco for almost nothing. Once again, just buy a new one.

Tomorrow, I'll sand and paint it.


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Yo Stitch's 95,
Thanks for the advice!
 

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Discussion Starter · #19 ·
I made alot of progress today on my rear sill. I need to finalize the welding and repair some rust, but I think its important to test fit the tailgate first.

The rear body had to be raised a little over 2 inches.

Fortunately, the rear sill on my 88 is fine, so I was able to use some of those measurements.


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Coming along nicely... Go you 👍
 
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