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95 Rust Belt Bronco Rehabilitation

14032 Views 135 Replies 11 Participants Last post by  Stitch's 95
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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Hi @Stitsh's95 whatI am trying to get a look at is te Body mount that is fixed to the trucks cab
I gave the cab floor to a friend of mine last week. He was planning to cut some patches out of it and should still have it. I cant make any promises but I'll ask him to send me some pictures if he hasnt put it in yet.

I did take this picture before he took it. It shows the mounts that are behind the seats.


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What a transformation Stitch. Kudos to you to put this much work into the FSB and bring it back to life.
Thank you. I didn't have any idea what I was getting myself into. I have learned a lot and have found the process extremely rewarding.

I'm far from done, but I couldn't have gotten this far without this forum and everyone that has contributed to it. I'm also grateful for everyone that has been patient enough to answer all my questions.

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I gave the cab floor to a friend of mine last week. He was planning to cut some patches out of it and should still have it. I cant make any promises but I'll ask him to send me some pictures if he hasnt put it in yet.

I did take this picture before he took it. It shows the mounts that are behind the seats.


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Thanks , might not be too hard to fab.
Well I hate to say it but I put a set of relatively tiny tires on the bronco. I'll have to snap a picture but 31s don't look right with a 6 inch lift.

I havent been driving this much because the front tires have started to dry rot beyond what i was comfortable with. The back tires are several years newer and in good shape but I also wanted new tires for the 96. I was also getting sick of swapping the tires every time I wanted to put it in the garage. Fast forward and I put the tires that were on the 96 on it.

Hopefully this temporary change will make it a little easier to do smaller upgrades and repairs while still have safer tires to drive it.

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Had a great day at the junk yard today. Found an almost untouched 93 f150 that had been tboned. I spent about 6 hours pulling parts that I will use on either this or the 96.

The prize was the radiator core support. Both broncos need one.

Also found newer speakers, great bumper, aftermarket headlights/taillights that looked almost new, and a grill that is in great shape.

I also pulled all the switches that I could reasonably get to and got 2 wheels. One of the wheels had an almost new tire it. View attachment 210370 View attachment 210371
Automotive tire Automotive lighting Motor vehicle Automotive design Hubcap


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Well I'm back to work in the garage but I'm gonna press pause on the bronco and finish my fairlane. I have worked around it for two years because I never felt prepared to tackle the wrinkled quarter panel. It has sat in the side of my garage for 20+ years. It was driven into the garage so hopefully in a few months I can drive it out.

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I think I'm gonna have to post the pics from my computer. Tapatalk is trying to insert everything incorrectly.

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Motor vehicle Hood Vehicle Car Automotive design

Motor vehicle Hood Automotive tire Automotive design Automotive exterior

Wheel Tire Car Vehicle Motor vehicle

Wheel Tire Car Vehicle Motor vehicle

Wheel Tire Automotive tire Hood Motor vehicle

Vehicle Motor vehicle Hood Automotive design Car

Tire Wheel Automotive tire Vehicle Tread


If all else fails use the website. Still dont know why the pro version of tapatalk isn't working.
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I still have a few smaller jobs to complete before I jump head first into the Fairlane. The biggest is dealing with the tailgate. The tailgate that was on it when I got it is rough. I lucked up and found one in a junkyards that was OK and cheap. It has some spots but I have been able to use it.

Biggest problem with the junkyard gate is that the straps at the top are broken so it let's water in. Somehow the water makes its way into the bronco by coming out through the access panel. I wouldn't have believed it if I didn't see it.

Since I have my garage staged for the Fairlane I can't park the bronco inside. That leaves me fixing the old tailgate instead of the better junkyards gate.

Here are the pictures. It's definitely too far gone from a time/cost perspective but I'm gonna cut it open anyway. I still want to practice patching before I try and patch the hole in the Fairlane. If it comes out well it will just be a bonus. If it doesn't I will probably pick up a new one next time I'm in Charlotte. I hate paying truck freight when I have friends close to the NPD warehouse.

At some point the window was replaced. I'm guessing it was when the torsion bar snapped. It was just taped up on the end. Not sure what that helped. The torsion bar brackets were mostly gone. Fortunately I do have another set. I was very happy that the window channels were in good shape. I don't have a spare set of those. I do have new felt on the way. View attachment 213809 View attachment 213810 View attachment 213811


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Got the bottom face off of the tailgate. Haven't decided if it's better or worse than I expected but from a cost/time perspective I guess I should go shopping. On the other hand. I want to learn and have plenty of metal shelving to use for material....


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Got the bottom face off of the tailgate. Haven't decided if it's better or worse than I expected but from a cost/time perspective I guess I should go shopping. On the other hand. I want to learn and have plenty of metal shelving to use for material.... View attachment 213843

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I think this is an instance where you need to splurge and get yourself a new tailgate. I repaired the one on my 86 XLT and it turned out ok but I also wasn’t planning on keeping it for long either. I know it would be a matter of time before any rust I missed started to come through.


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@robbz28 funny you mentioned that. I just left NPD.


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Haha, I was thinking the same thing!! A nice new one is a much easier fix! I know shipping on them is expensive tho, Glad an NPD was close for ya!
I agree that the old one is too far gone. I'm just and engineer and like to fix things. I guess that's why I entertained fixing it so long..

I met a guy at the bronco show who had fixed on in a similar condition. It is holding up 7 years later but was also sand blasted.

I'm not normally this close to an NPD but we are in Charlotte visiting some friends. When I realized the NPD had them in stock and was 10 miles from their house the decision was made.

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Just about have the new tailgate together. I got most of the internals in after I snapped the pic. Hopefully I'll get the face painted tomorrow and will get it installed Monday.

Went with the clear rustoleum bedliner material that I used on the interior. It seems to be tough enough. I will skip that part on the outside.



I tried posting a picture but tapatalk is still throwing the view attachment link without the picture.
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Trying the picture again.


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