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ate lug
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8,432 Posts
Discussion Starter #61
Yeah times flies, its hard to believe hes already 6 months old now. Mom says he's just like his dad- a ball of fire who cant sit still for more than 5 minutes :toothless


No real progress on the bronco. Weve been doing some work on my buddies XJ, along with some more work on his brewing stands, and now im working on the floor in the kitchen/foyer. Hopefully ill have a progress update to this thread before xmas.
 

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89 Problems
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2,544 Posts
WOW that york mount is awesome! I picked up a 210 in a junkyard the other day, mine is a bit easier since I can use the BroncoAir pulley, but I think I am going to make a mount bracket myself. very cool. :thumbup
 

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ate lug
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8,432 Posts
Discussion Starter #66
Thanks guys :thumbup

The broncoair stuff is nice; ran it on my 351 and it worked great. While it would fit on this motor, theres no room for the York with the wider 460. Hopefully this bracket works out, time will tell.



Well i promised an update around Xmas, so here it is:

First things first: Reinstalled the brake booster/master on firewall and then removed the steering column in trade for my original column. I also managed to find an 87-91 wheel w/o the cruise buttons which will be going on at a later date



So, then this happened:

Front clip + 42s back on!!!


Truck is so big, the garage door wouldnt open if the hard top was on :toothless



The front clip was inevitable. I needed the 42s on though. Since i want it to be a bit more streetable, last year i bought a set of Bushwacker cut-out flares. But, i dont like the look of the 87-96 flares, so i bought 80-86 instead. Since they technically dont fit, i couldnt follow the directions to install them. So instead i needed the tires on the bronco so i could figure out where the flares actually need to go. So, here we go!


I started at the rear left, because gas filler door.
Cardboard mockup of sheetmetal to be removed:


some rust thats gonna have to go:


Bam! Flare mocked up!


Its impossible to get good pics with this side against the wall.
I have the filler door cut and sitting on my work bench, need to get that reinstalled.


Passenger side installed!


Looks good, i really like the shape of these flares


They just barely cover the tires


With the rear done, i can move on to the front:


This shows the absolute minimal amount of sheetmetal you can remove to install the flares. Its mostly in the corners






Flare mocked up


The corner will get cut off, but not till way later down the road, when i get around to building a front bumper




The money shot: This shows how much more material i can remove w/o impacting the install of the flare. More on this later.


Driver-side cut


Rust: repaired :toothless




So, here's the plan. Once all 4 flares are 'installed', ill then remove them. Plan is to install riv-nuts in the fenders, and use machine screws to hold them in place. I want to be able to easily remove them when i go wheeling. Theyre too expensive to smash on a tree!

So, back to these two pics:

This actually looks like a pretty good amount of room for the 42s. Most of the clearance issues i ever had were at the corners anyway, not at the top.


However, as you can see from this pic, theres lot of more sheet metal i can remove, and still be able to reinstall the flare:


So the plan now is to open the wheel wells up a tad bit more, install riv-nuts and then weld them back together again. My goal is to have a nice open wheel well for wheeling, and then install the flares over top of them for when im not offroad. But before i can cut the wheel wells any further, i need to reinstall the fender liners, and see what i can get away with. Thats why im doing the front first; once i get a final shape to the fronts ill remove the rear flares and do the same. Then the flares can go back in their boxes, and the 42s can come back off, until way later down the road.
 

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ate lug
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8,432 Posts
Discussion Starter #69
Progress!

I was trying to install the fender liners to see how i want to finish the cut on the fenders. But, the core support was repaired by the previous owner, and i wasnt thrilled with the job he did, so i said screw it and ordered a new one from LMC. So that delayed me a bit.

Ginormous box!







Old core removed...


...and new one installed!


Modifying the core body mount brackets for tire clearance







While i was waiting for the core support to come, i started on the floorpan repairs

This is the worst spot ont he whole body, already cut out.


This is the next worst spot. Once these two are done, itll just be minor repairs.




Here i have to pause; ive got t-case issues in the 96 that ive got to deal with.
 

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ate lug
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8,432 Posts
Discussion Starter #70
SO i pulled the front clip back off. The first cut to the fenders that i made, was the bare minimum to fit the cutoff flares. Now the plan is to remove two more inches, which is about as much as i can remove, and still be able to reinstall the original fender liners. So here we go!

Line drawn, and a whole ton of tabs cut


The process of bending them over begins




All tabs bent, heres roughly what the fender will look like when the flare is removed


after a whole sh*tload of welding & grinding, both fender panels are now rewelded


This shows you how much more material is removed.


Made a template of the new wheel arch, and transferred it to the other side


A ton more cutting, bending and welding!




Finally got some primer on them the other day.


If all goes well ill be able to get the front clip reinstalled sunday, and i can then begin working on the fender liners. Theyre gonna need to be trimmed up a bit now that the wheel well is bigger. I also need to install rivnuts for the flares. Hopefully i can get both done by the end of next week, we'll see!
 

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ate lug
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8,432 Posts
Discussion Starter #71
Tragedy!

I was moving the front clip, and bumped into one of my shocks. It fell over and this happened

:doh0715: Guess ive got no excuse now, were upgrading the shocks.

Front clip reinstalled! Wheel well is pretty big now.


I installed the fender liner (Yes its actually bolted into place in this pic). Its gonna need some work if im gonna reuse it!


Also got my riv-nut tool, so i can start installing the nuts for the flares :cool:


Im gonna start working on the fender liners next i think. Gotta get a game plan going. Currently thinking im gonna roll the seams on the firewall, then trim up the fender liner, and maybe make a piece that will seal the back to he firewall. Dunno yet. Long term use proved the tubbed wheel wells i did last time were a nightmare for shedding heat, so this time i want to make sure i leave as much open space under the hood as i possibly can.
 

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ate lug
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8,432 Posts
Discussion Starter #72
So i had some time to play with my rivnut tool. Its actually really easy to use, so ive got about half the rivnuts for the passenger flare installed


Still need to order the final hardware; theyll be 8-32, and i want to use stainless button head screws mainly cuz i think theyll look cool when installed :toothless

I installed the OEM battery tray, it just fits


Same as the bracket for the airbox


So it looks like ive removed as much as you possibly can, to still reuse these brackets :toothless
So the plan is to get some 1x1/8" flat stock and build some brackets to attach sheet metal (or maybe even sheet plastic) to to build inner fenders. But first, i have to finish this:



Started cutting down a ginormous chokecherry tree because its a messy tree thats mostly hollow from years of carpenter ant abuse, and its also where i want to put a shed this summer. So once i get this thing all cut up and the stump ground down ill jump back on the bronco. So many projects, so little time.
 

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14,426 Posts
Digging the work you did on the fenders..s**t ton of work, but they look great.it's giving me some ideas..I'm realizing there's no way around the fact that I'm going to have to pull the fenders and cut a fold mine they just look sloppy the way they are..
 

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ate lug
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8,432 Posts
Discussion Starter #74
Ugh its so much work :toothless Im gonna guess ive got 12 hours into the cut & reweld, which actually isnt that bad i dont think.
I used a square and sharpie to draw a rough cut line, and then the fastest way to cut the tabs was actually a grinder since it wont dig in like a sawzall does. Hammer & pliers to bend em all over, and lots of on-the-fly- cutting and grinding to get the tabs right for welding. The Mig makes short work of the job; last time i did this i did it all with my stick welder with 1/16 rod. So much slag to chip!

The fenders will need some cleanup & bondo work prior to paint, but all said and done, i think they came out pretty decent for a 'wheeler.
 

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ate lug
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8,432 Posts
Discussion Starter #76
Yeah they're pretty neat. You can get pretty much any size/thread you want, and pretty easy to install.

Last time I ended up adding a whole bunch of holes to the fender liners right in line with the headers to help evacuate heat, I will probably do the same again.
 

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Premium Member
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34,691 Posts
I have been planning to use the same nut-serts to install my LUND visor. Since you've just used 'em... how do you think they'll do for the job. I really liked the idea that I could remove and re-install the visor easily if needed for a cracked windshield swap, without causing potential leaks like sheet metal screws or regular rivets would/could.
 

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ate lug
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8,432 Posts
Discussion Starter #78
Ive been playing around with em, set a few into a piece of scrap sheet just to see how they work. Drilling the correct hole size is crucial to them holding. But once theyre crimped, there is no chance of ever pulling it through the hole. You can get them in both AL & steel. The AL ones are very easy to crimp, easier than using a pop rivet gun, altho you have to be careful because you can actually rip the threads out of them with the tool while crimping it. The steel ones are harder to crimp of course, but once done, its there forever. The 8-32 riv-nuts im using have ~ 1/4" of thread, so theyll hold far better than i need for a set of fender flares.



This is the crimper i bought:
https://www.amazon.com/gp/product/B003TODXQW/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1
Comes with a bunch of dies & riv-nits, but not 8-32; that i bought separate (also from amazon)

Attached is a pic of the backside of one of the 8-32 nuts crimped. Looks good once done. When youre using them, youd think you were threading a screw into a tapped hole not an insert. I love em, im gonna end up using these things everywhere :toothless
 

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Premium Member
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well thanks for the feedback. I bought the exact same kit back when I still had the '90 based on a recommendation from @schwim but the LUND visor I picked up turned out to be cracked up pretty badly and when I tried to fiberglass in the cracks, the fiberglass mix I used didn't bond worth a damn, so I never tried to mount it. good to know they're working out so well. I've also been considering using them to mount my "oh sh!t" handles for the little lady. glad to hear the setup was a solid investment. :thumbup sorry for the hijack. :toothless
 
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