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Discussion Starter #41
Thanks guys! I did start looking for a real nice rust free Bronco. Then as it does, life happens, and my budget was cut in half, I was able to barter for this one, so no cash out of pocket left the budget intact. I have done much more to save a Chevelle and knew I could do it! Plus my 10 year old son now knows what it takes. Hopefully he will someday make too much money to worry about such trivial things as these but if he does he will still be able to, and not afraid to do it!

I have been thinking about getting some of the proper metal woking tools, an English wheel, a shrinker stretcher set, and a planishing hammer. I have always enjoyed making something from nothing!
 

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Well spent some time cleaning up the mess in the garage tonight, just as I was getting ready to back the Bronco out I noticed some space under one of the body mounts. Further investigation proves my worst fear, more rust. I was not going to pull the body off the frame but I am really considering it now. I figure the front end is going to be off of it I already have the rear mounts off, what more is there. Plus it will only make it that much nicer when its complete. What do you think? Should the body come off?



Bronco outside for the first time in two weeks. Its a lot healthier now then when it went in! Sorry for the dark picture I did not take the good camera!
 

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First off, Excellent job with the Fab Work. Not everyone has the patience and skill to pull that off.

I would say you are so close to getting the body off any way, if you have the tools and facility to lift it off without messing it up, I would go ahead and do it. More than likely your body mounts on the frame are completely rusted out and need to be replaced anyway. JBG has some frame saver mount patches that work great.

http://shop.broncograveyard.com/Frame-Saver-Bronco-Complete-Kit-Set-of-10/productinfo/33108G/




Plus with the body off, it will give you a chance to clean up the frame and hit it with some POR15. While you have the Rear Quarters off, Make sure you hit the entire inner skin with POR15, I would also do the inside of the new quarter panels as well. Then they will never rust again.
 

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Discussion Starter #44
That's exactly what I'm thinking too! I did not want to get that far in but I think I past too far in about 5 patches ago! POR15 thou is not what I was thinking about, I was looking into chassis saver vs POR15 seems like both are good products.
 

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either one will do great. Ive never used chassis saver, but it looks like a good product as well. Most of that Eastwood stuff is pretty good.

Plus when you have the body off, You could do some clean up on the under side of the tub and hit it with some bed liner. That should also help stop any future rust. One of these days when I get my body off, Im going to have the bottom side blasted clean, then take it to line-x on a rotisserie and have them do the whole underside after I paint it with some DP90 epoxy primer.
 

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Yeah this is cool buddy. Was gonna ask if you had shares ina mig wire company :thumbup. There is something about tearing into a bad truck and patching it back up. Had an old Nisan patrol once did the same thing with my son to get it back to where we could go 4wding. was great fun both the work patching and the driving. 1 full sheet of sheet metal though and quite a few hours. Great job so far. Real keen to see what she ends up like.
 

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Discussion Starter #49
The List

Remove rear Bumper
Repair rear floor
Repair floor seams
Repair wheel arches
Remove quarters
Remove wheel housing
Repair wheel tubs
Repair the kick boxes
Remove rocker panel
Replace drivers floor
Replace rocker panel
Repair Corners under tail lights
Remove front end
Remove tub from frame
Repair body mounts as needed
Weld in small patches in tub as needed
Fabricate bucket seat mounts
Clean outer tub area
Clean inner tub area
Clean rear frame rails and under carriage
Remove 9" rear
Install new springs and shackles
Install 10.25 rear
Reseal and rebuild brakes on 10.25
Replace brake lines
Install new drive shaft U joints
Install rear front spring perches
Install front spring perches
Install rebuilt steering gear box
Box front frame rails
Fabricate Winch mount
Fabricate snow plow mount
Install new front springs and shackles
Install D60
Reseal and rebuild brakes on D60
Paint frame rails and undercarriage with chassis saver
Paint inner quarters with chassis saver
Paint inner outer quarters and inner tub with etching primer
Paint inner tub with Bed Liner material
Remove doors
Rebuild door hinges
Tune up engine
Replace all fluids and filters
Install second charging system
Install two new battery boxes
Install nose onto Bronco
Paint prep
Install new bucket seats
Fabricate a new center consol
Install doors
Install interior
Primer sealer unit complete

Some of this stuff is already done! The rest needs done........
 

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Discussion Starter #50
No pictures to add but I did get the bottom of the passenger side B pillar done last night, it was way better then the drivers side! Also fit a patch to the floor of the area just inside the B pillar on the passenger side, I am calling these the kick boxes. Tonight I hope to get the small patches in the floor on the passenger side done and the drivers side kick box floor. Friday will be rear cross member day and Saturday will be take it off the frame day!
 

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Discussion Starter #51
Another 2 hours in the garage!







Got to post some pictures this evening, got 3 more patches installed into the passenger side floor board and started to strip off some of the PO's bedliner material off of the outside!
 

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Discussion Starter #52
I'm Broken

Made it to the garage today!




Honestly thou this is where I said, I hope I can put this back together! Everything was gone!




Put the cap on by myself and screwed up my lower back pretty good but pushed thru then I ran out of argon before I had a chance to finish everything up. Ran around town looking for anyone open that might have it, no one was open......
Going to start pulling the body off tomorrow since I have no argon. Till then.
 

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Discussion Starter #55
I was concerned to say the Least! I actually did do it in steps measured and test fit and measured, fit again then beat on it a little, then measured and started welding! After it was welded I removed all the clamps / spreaders and what do you know, it stated! I need to find some tailgate latches anyone know where I can get them?
 

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Wow that is some brave work, well done
 

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Discussion Starter #58
Still Broken

With back pain still kickin, I stayed away from the garage yesterday. Today thou I could not stand to sit around any more. I got some poster board and made my way to the garage. I messed around with some of the ideas I have had for the overhead shelf and the overhead consol.



I like the large face gauges rather then the little ones that are hard to read, what do yinz think? This is all rough of coarse just mocking it up to see what its gonna look like. I like the size and fit so far but not sure about the gauge placement.
 

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Discussion Starter #60
Rear Floor So Far

In order the following pictures show how I attacked the cancer in the rear of my 85 Bronco. This is part 1, part 2 is currently underway but not finished. This may seem spastic and unorganized but I did flow thru the repair from the known good areas to the worst and most complicated pieces to be sure they all made it back were they belong. It was a major repair but with patience and will power it can be done by anyone that can weld, if you can put down a nice even bead of caulking you can weld. Don't let it scare you, measure it, look at it, plan your next move and keep moving. Each step builds on the last and eventually you'll reach your destination. I'm not there yet but way closer then I was three weeks ago! You can do it!





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