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Arizona Blue Line Build

3134 Views 67 Replies 13 Participants Last post by  Vicky Tu Tone
4
My plan for my 92 XLT Bronco is to take it from mostly stock original to slightly custom but completely drivable and reliable. I’m calling it the Blue Line build because I intend for this Bronco to be the Ivory to my Ebony. The Ivory is Oxford White ext, charcoal int, with minor upgrades from stock to front suspension and 4” lift. The Ebony is my 2011 Crown Vic, retired Elkwood City, CA police car (black ext, med flint int, aluminum K9 box in rear seat area, P71 package). I am also retired LEO so blue naturally becomes the accent on nearly everything I own. My husband is just happy I don’t like pink! So keep watching for the changes and the blue!
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Clean looking Bronco! (y)
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Yo Vicky Tu Tone,
Great looking 92!
Congratulations!
Al
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also retired LEO
(y)

We have another retired LEO down in AZ, @Blue1551 . He and his wife are great folks. He is up in the mountains somewhere.
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Finally had an ah ha moment and figured out how I can post pics of my paint ideas I’m working on in Word. “Take a pic of the computer screen!” Duh:/ Here’s the first one I made up. Definitely not doing turquoise though. It’s sort of a short version of the Victoria Two Tone prior to 1989
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First fixes are in the books. We removed the visor to allow the windshield to be replaced. Remarkably, no rust found around the bolt holes in the roof. But some jackwagon spread silicone across the top of the windshield frame and roof gap. Apparently that was the best way they could think to stop water leaks caused by a severely damaged windshield and 30 year old windshield seal. Because replacing the windshield would be too difficult, right?! Anyway, lots of massaging the silicone and I finally got it all of the roof and the aluminum trim. Paint on the roof is discolored from all the dirt and crap trapped under the visor, but I will take care of that later. Pulled the upper interior trim and headliners out.

Windshield guy took out the windshield and removed most of the original sealer. Found a significant amount of rust, surprising, right?! But he is an old car fan, so he agreed to stop there and let us take care of the rust before he returned to install the windshield. I got working on the rust, never did anything like this before, so YouTube was my friend. Had to buy a tool, I know, shucks!!! No rust holes in the metal, so ground it back as much as possible, treated with rust converter, and primed it over the next few days. New windshield installed today. The guy was impressed with my prep. I figure it should last the rest of my lifetime, if it lasted 30 years the way it was.

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Next, the hubby tackled the pinion leak. Pulled the pinion seal and found the bolt loose. While we waited for the new seal to be delivered to our parts store, pulled off the diff. cover. Found two bolts loose. Full of water. Not good. Cleaned and inspected it, not much metal, surprisingly. Found the vent tube zip-tied to the frame next to the left tire. Blew it out, and seemed to be clear. Put it back where it belongs tucked under the rear body. Replaced the pinion seal and torqued the bolt. Replaced diff. cover and filled diff.

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I'm skipping lots of steps, so don't attack me. My hubby knows this stuff, I'm just the morale support and tool fetcher most of the time unless it takes a small hand or some finesse.

While we were under the truck, replaced the cracked/torn rear sway bar bushings.

I got inside while hubby was working and removed the bolts holding the roof rack on the hardtop. We had already pulled a CB cable and wires for a light bar out of the roof. So now I have 10 holes to patch before I can wash this filthy thing.

Also took note of the hillbilly exhaust. Apparently the pipe rotted off, so probably same jackwagon stuck a smaller pipe in what was left of the old pipe then stuck a chrome tip on the end of it just over the rear axle. That will have to be fixed before we can take it through emissions. They won't test it if they can't reach end of exhaust without getting under the vehicle. But we have lots more to do before we are ready for emission test and registration. Won't be drivable for a while still.

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Making progress!!
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Are you planning to reinstall the visor?
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Are you planning to reinstall the visor?
Yes! I like it clean, but the holes are a problem and it is actually quite beneficial in AZ. So after I clean up the paint a bit, will be reinstalling with good sealer around the bolts. The PO did a great job of sealing the original install to prevent water and rust so I’m hoping to do so as well.
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Look into rivnuts. Water tight and I think woud make for a cleaner installation.

Are you on FacePlant? There is a really great group of guys in Az, with a big concentration in the Phoenix area that are all Bronco guys. Arizona Bronco Club. Tell Fred we sent you.
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Here’s a little background on the Blue Line Project Bronco. And I emphasize “little.” It was purchased by original owner in Centralia Washington. Spent 8 years with that owner. Sold to 2nd owner in 2000, also in Centralia, WA. Sold to 3rd owner in 2003, in Centralia,WA. Stayed there until Jan 2021. No maintenance records on Carfax for that period except registration every year in WA. Found receipts in glovebox for tires and 4” lift plus suspension upgrade in May 2000.

Sold to 4th owner and registered in AZ in Jan 2021. Had work done in AZ on brake master cylinder and booster. Sold to 5th owner in Dec 2022. He put the current tires and wheels on it. Changed his mind about restoring it. So we bought it in March 2023. Fun fact, it was driven 50 miles between Jan 2021 and March 2023.

Seems to run fine. But we are going through and checking everything before we get it registered and start taking out on the road. We are used to old trucks. Currently have a 1972 F250 2WD, a 1977 Chevy K20 4WD, and my 2011 Crown Vic. So, this is just another project for us to get reliable.

We don’t flip our projects though. We have only sold one actually. And only because we sold it to the wife of the original owner when it was brand new because she was buying all her husband’s old farm trucks and giving them back to him a gifts. She had been hounding us for years, and we finally caved in.
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First fixes are in the books. We removed the visor to allow the windshield to be replaced. Remarkably, no rust found around the bolt holes in the roof. But some jackwagon spread silicone across the top of the windshield frame and roof gap. Apparently that was the best way they could think to stop water leaks caused by a severely damaged windshield and 30 year old windshield seal. Because replacing the windshield would be too difficult, right?! Anyway, lots of massaging the silicone and I finally got it all of the roof and the aluminum trim. Paint on the roof is discolored from all the dirt and crap trapped under the visor, but I will take care of that later. Pulled the upper interior trim and headliners out.

Windshield guy took out the windshield and removed most of the original sealer. Found a significant amount of rust, surprising, right?! But he is an old car fan, so he agreed to stop there and let us take care of the rust before he returned to install the windshield. I got working on the rust, never did anything like this before, so YouTube was my friend. Had to buy a tool, I know, shucks!!! No rust holes in the metal, so ground it back as much as possible, treated with rust converter, and primed it over the next few days. New windshield installed today. The guy was impressed with my prep. I figure it should last the rest of my lifetime, if it lasted 30 years the way it was.

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Next, the hubby tackled the pinion leak. Pulled the pinion seal and found the bolt loose. While we waited for the new seal to be delivered to our parts store, pulled off the diff. cover. Found two bolts loose. Full of water. Not good. Cleaned and inspected it, not much metal, surprisingly. Found the vent tube zip-tied to the frame next to the left tire. Blew it out, and seemed to be clear. Put it back where it belongs tucked under the rear body. Replaced the pinion seal and torqued the bolt. Replaced diff. cover and filled diff.

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I'm skipping lots of steps, so don't attack me. My hubby knows this stuff, I'm just the morale support and tool fetcher most of the time unless it takes a small hand or some finesse.

While we were under the truck, replaced the cracked/torn rear sway bar bushings.

I got inside while hubby was working and removed the bolts holding the roof rack on the hardtop. We had already pulled a CB cable and wires for a light bar out of the roof. So now I have 10 holes to patch before I can wash this filthy thing.

Also took note of the hillbilly exhaust. Apparently the pipe rotted off, so probably same jackwagon stuck a smaller pipe in what was left of the old pipe then stuck a chrome tip on the end of it just over the rear axle. That will have to be fixed before we can take it through emissions. They won't test it if they can't reach end of exhaust without getting under the vehicle. But we have lots more to do before we are ready for emission test and registration. Won't be drivable for a while still.

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Nice work around the windshield! I found were my PO siliconed between the dash and windshield (bang head). I must of looked around for an hour for a screw I might have missed before seeing the clear caulking holding it down. Good on you for knocking that out as a couple I’ve gotta get my wife on board but something about 4 kids between 2-8yo tells me she won’t be very interested. Congrats on the beauty
Nice work around the windshield! I found were my PO siliconed between the dash and windshield (bang head). I must of looked around for an hour for a screw I might have missed before seeing the clear caulking holding it down. Good on you for knocking that out as a couple I’ve gotta get my wife on board but something about 4 kids between 2-8yo tells me she won’t be very interested. Congrats on the beauty
I’m not like most wives. Guys are always telling me they wished their wives or girlfriends were interested in this kind of stuff like I am. I remind them there is a trade off to enjoying this stuff. I don’t cook and I don’t clean much. So, if you want her to take care of those kids, and other stuff, don’t be too disappointed if she would rather not get greasy with you. But thanks for the compliment. It was better for the bronco for me to do it anyway. My hubby is almost 300 lbs and so is our glass guy. They could never sit on the hood without crushing it, or lean over it for hours without destroying their backs. It was easy for me. And besides, it’s my truck, so…
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I’m not like most wives. Guys are always telling me they wished their wives or girlfriends were interested in this kind of stuff like I am. I remind them there is a trade off to enjoying this stuff. I don’t cook and I don’t clean much. So, if you want her to take care of those kids, and other stuff, don’t be too disappointed if she would rather not get greasy with you. But thanks for the compliment. It was better for the bronco for me to do it anyway. My hubby is almost 300 lbs and so is our glass guy. They could never sit on the hood without crushing it, or lean over it for hours without destroying their backs. It was easy for me. And besides, it’s my truck, so…
Good on ya, and I ain’t knocking her, we all have our superpowers, hers is being Mom. She can’t wait till I’m done with my resto though. She enjoys the drive with the whole family in the truck.

4 kids, two dogs, a dirt road with the windows down is our paradise. She sent me this last night while I was in the garage lol.
Hair Head Smile Hairstyle Facial expression

PS Keep up the good work, she looks great! One project at a time. Look forward to seeing the progress.. I need to get around to posting mine.
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Looking good so far. I second the rivnuts for the Visor. I just took one off an old F250 and installed it on my sons F150. I used stainless rivnuts. They are much nicer than a self tapping screw.
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Good on ya, and I ain’t knocking her, we all have our superpowers, hers is being Mom. She can’t wait till I’m done with my resto though. She enjoys the drive with the whole family in the truck.

4 kids, two dogs, a dirt road with the windows down is our paradise. She sent me this last night while I was in the garage lol.
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PS Keep up the good work, she looks great! One project at a time. Look forward to seeing the progress.. I need to get around to posting mine.
That’s awesome! That mutual love of dirt roads is what got my husband and I together 41 years ago. Keep up the good work, your thought process is spot on! And I would love to see your truck too!
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Look into rivnuts. Water tight and I think woud make for a cleaner installation.

Are you on FacePlant? There is a really great group of guys in Az, with a big concentration in the Phoenix area that are all Bronco guys. Arizona Bronco Club. Tell Fred we sent you.
I tried to find the AZ Bronco Club on that platform. But there are sooo many and none with exactly that name. Looks like most of the groups emphasize group rally’s and shows. I’m not big into meeting up with big groups. Kind of like solo driving with the hubby or a few old friends. And definitely don’t like crowds so I avoid car shows and such. I really like research and learning from others though. So who knows, I may find that group.
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Here is a link for you if you want it.
I was in the group for about a minute but found that
i am not so much into the faceplant social media aspect.
(too invasive for my taste.)

AZBroncoClub are a
Great Group of Bronco Enthusiasts from all over AZ
with Wildly diverse backgrounds and who are willing to
drive to and give "hands-on help" to Members in Good Standing.
(the Missus and I surely miss going out on runs with them).

AZ BRONCO CLUB | Facebook

Maybe @Blue1551 will pop in here due to similar retired Professional backgrounds.
(or a PM even)

Anyway,
Great Job on that windscreen area.

Good Luck
Dragon.
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I tried to find the AZ Bronco Club on that platform. But there are sooo many and none with exactly that name. Looks like most of the groups emphasize group rally’s and shows. I’m not big into meeting up with big groups. Kind of like solo driving with the hubby or a few old friends. And definitely don’t like crowds so I avoid car shows and such. I really like research and learning from others though. So who knows, I may find that group.
Fred is user @Quader1 here on FSB.com. He hasnt been in the best of health for a while now so he may not be very active over there either. @not a jeep is down there too. I met him and blue1551 in Moab. Both good guys. @itwasfree!!! was highly active down there before cancer slowed him down a bit. But i think (and hope) he is still kickin. Im like you, not much for large groups, but they can be fun. I had a grand ol time at the couple bronco events ive been to in Moab and Michigan. Everyone is real nice and friendly.

I feel like @BroncMom would enjoy this thread too... You sound like you'll fit in just fine here!

As for the visor, i used and have suggested riv-nuts or nut-serts for installing them. When doing so, i coated them with a small glob of architectural silicone caulk, including the threaded hole. Then screw the fastener in and it will be watertight. They also allow use of a 1/4-20 machine screw or bolt instead of a cheap grade two self-tapper.

And for the love of all that is holy, be careful with the visor! The original Lund models are no longer made and the Summit ones look like crap. And they are about 300 bucks on ebay or CL.
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