[Doosenberry]

Here's my temporary routing of the EFI hose. There's actually a small section of rubber hose that attaches the two lengths of factory steel line, so I replaced that while I was down there. Out with the old, in with the new kinda deal. Also a bonus shot of how low the headers hang in relation to the transfer case skid plate, etc, while I was under there looking towards the front. Not the best, but it is what it is.

 

[Doosenberry]

I dropped off the Bronco at the shop before leaving to work tonight, so they can make the rest of the exhaust tomorrow. I'm a bit paranoid that they're not going to do it the way I want it as I haven't spoken directly to the guy that does their exhaust work. I get off at 6:30 am and take my kids to school about an hour later, so I should still be up around the time the shop opens. I just want to confirm that they know exactly what I want. I don't plan to hang around or check in on the work, because I hate that crap at my job and I know it would irk me the wrong way if I was a mechanic and some customer was always lookin' over my shoulder so to speak.

So, hopefully, provided nothing gets lost in translation and they're able to do what I'm lookin' for, it'll go 2.5" pipe from the collectors into a Y over the crossmember, O2 bung where Holley wants it located within 1-10" from the collector and pointing at least 10* north of horizontal, then 3" single in and out of a Magnaflow muffler and exiting in the stock location. I'm wanting the exit to be similar to what deathmobile2 has on his Bronco for maximum clearance off road. I'm tempted to just print a picture of his and take it in with me and say here, do this.



Here's deathmobile2's

 

[PowerB]

I would bring in the picture. I think it’ll help convey that tucked look that you want. I really like it. Great build thread

 

[Doosenberry]

I would bring in the picture. I think it’ll help convey that tucked look that you want. I really like it. Great build thread

Thanks. I'll probably print off those shots before I leave work and take them with me. I think the rest of the pipe routing will be self explanatory.

I'm still not sure of this being a build. I feel pretentious calling it that when compared to what other guys are doing on here. So far it's a repair thread. Once I create the bracket for my fuel pump I'll call it a build. At that point I'll have actually made something!

 

[kubotaorange76]

Looking good,

Might want to address worn that clutch linkage soon, i had one eventually break on me

 

[Doosenberry]

Looking good,

Might want to address worn that clutch linkage soon, i had one eventually break on me

Yeah I noticed that too looking at the pics after I took them the other day. The shop that put my headers on removed the linkage to create needed room or so I was told. The clutch pedal doesn't throw the same anymore, so I'm not sure what they did. I'm gonna mention it when I go back in to pick it up actually. They were balls deep in customers when I got there at 8 when they opened.

I'm kinda annoyed with the guy who's gonna do the exhaust though. I showed him the print out of the pics I posted on here and he said it was going to look bad. Sorry deathmobile2, that guy says your exhaust is bad. I reassured him that's what I wanted. I really like the owner, but this mechanic is kind of a prick and this isn't my only time dealing with him. I offered to leave the pics with him for reference and he turned me down. I really hope he does it the way I asked.

 

[reptillikus]

Yeah I noticed that too looking at the pics after I took them the other day. The shop that put my headers on removed the linkage to create needed room or so I was told. The clutch pedal doesn't throw the same anymore, so I'm not sure what they did. I'm gonna mention it when I go back in to pick it up actually.

Well, for starters, the bushing for the linkage is gone. If they disconnected it there then they probably tore it when taking it apart, as is prone to happen. But, its a cheap part, and they should have replaced it during reassembly.

 

[kubotaorange76]

The hole in the zbsr is worn very oblong. Bushing wont last

Fill with weld and redrill, same goes for rod, its probably got a groove in it as well.
Other option is to make new rod using rod ends and bolts (heims). This gives a cery smooth feeling clutch


That guy is planning to do it his way, doesnt want to be told what to do. I would get it away from him if you really want it done like you do.

 

[Doosenberry]

Exhaust is done.

I mounted the EFI throttle body, installed the O2 sensor, installed the temp sensor, and did a few other little things. I'm still in the process of finalizing the routing for the main EFI harness. I don't really want to clutter up the passenger side inner fender with more relays and fuses than I have to. I'll make my fuel pump bracket, mount and wire up the pump, and finish out the fuel system. I plan to have it all running next week since I'm working this weekend. We'll see how it goes. I tend to over-estimate how quickly I can do things.

 

[Doosenberry]

Since I don't have any pics of what I did the past couple of days I'll share some of the other stuff I did to the Bronco last year.



I removed the transfer case skid plate, cleaned it, painted it, and put it back on with new hardware. It was pretty nasty.

The number off the skid plate if anyone needs it.

I also rebuilt both driveshafts as inexpensively as I could. I cleaned them, painted them, replaced all the u-joints, and rebuilt the double cardan CV yokes rather than replacing them since they are about $50, $45 a piece for a spicer unit from JBG, and I have one on each driveshaft. JBG currently sells just the centering ball and spring for $13. I'm looking at their website right now and to buy 2 of those and ship to my zip is $33.55. Even with JBG's shipping prices that's less than buying one complete unit. Rebuilding them was a bitch though. My priority was on the front shaft. The first time I used 4wd on the Bronco after I bought it it sounded like I was on a roller coaster going up hill. Click click click click click. After rebuilding the shaft that was gone, so whatever was clicking clicks no more. Had to use my 75 F150's tailgate as a work bench at the time, along with the kitchen counter for reassembly. This was my first time ever doing this, I had never even changed a u-joint before, so I dove right into the unknown. I've since expanded my tool repertoire, so this would be a lot easier for me now had I done it today. Who the hell wire brushes a driveshaft with a toothbrush sized wire brush? This effin guy. You'll also notice that I got creative with where I hung things to let the paint dry, I have more ingenuity than I do space and tools, plus it always seems to rain when I'm painting parts for this pos.

The hardest part of rebuilding the CV was removing the sleeve that holds the ball. It was basically welded to the housing is sits in by corrosion. I took it to a shop that does driveshafts and simply asked the guy there for advice and nothing more since I didn't want to buy another CV and didn't want to pay someone to do what I was trying to do myself. He took it out of my hand, looked at it, put it in a vise, tack welded for spots around the inside of that sleeve (north south east and west), slid the end of a slide hammer behind the welds and popped it out with two strokes. He handed it back to me and told me to have a nice day. It took about 30 seconds of his time. I was like, why didn't I think of that. Oh yeah, I don't have either of those things. I used my little wannabe dremel to remove the other one once I got around to rebuilding the other shaft a month or so later. Loads of fun...

Not the greatest pics, but that's what I have in my archive it seems.

 

[Doosenberry]

Here's the rear shaft right before the 21 gun salute. Poor bastard never saw it coming....

 

[Doosenberry]

I have to keep reminding myself that this Bronco is more or less a test bed for my F100. I'm willing to do things to this Bronco that I probably wouldn't to my F100 all for the sake of finding out whether or not I like the mod/upgrade and whether I want to do it to my F100. Especially if it's irreversible. My gauge cluster was being a huge pos. Some of the lights wouldn't illuminate all the time. Some of the gauges quit working. I went through it and replaced the printed circuit board, repainted the needles and some of the silver trim, and replaced all the illumination bulbs (the ones that light the cluster, nothing else) with red leds. Why? Well why not? Lets try something different. It sure is.... different. lol

 

[Doosenberry]

I don't exactly have a nice set of clips to compare exhaust notes, but I'm gonna share what I have. I have a couple clips of me messing around across the canyon here in the lava rock from the middle of last year. I also have a clip I took last month when it was just open headers. The open header clip was longer, but I had to cut the beginning and end because the mic on the phone couldn't handle how loud it was and it sounds like blown speakers if I got within 10 feet of the Bronco. I don't wanna kill anyone's ears. You'll also get to see part of why I went with EFI over buying a new, smaller carb (750cfm is too much for this 351M). My Bronco would flood at angles causing a lot of surging and then I'd have to put in the clutch and rev it up to clear it out. In the first clip, if you have a computer and go full screen, you can see a little of the black smoke that comes out from the tailpipe.

Anyway, you'll get a little idea of the sound of the exhaust. When I get this thing running this week I'll take another clip with the new exhaust.




Stock manifolds and Y-pipe to about a 2 foot long glass pack.

Open Hedman chassis exit headers 89210.

 

[kubotaorange76]

Thanks for the clips, both sound good.

I completely understand the efi. Any sort of wheeling thats not straight line youll be spitting and sputtering. Motorcraft 2v and gjet are alot better, but they still have their limitations

 

[Doosenberry]

Thanks.

Yeah it wasn't fun going uphill, especially sideways like that first clip. In town it drove pretty well.

Before I made up my mind on EFI I actually bought a 4 -> 2 bbl adapter and put the motorcraft 2100 off my F100 on the Bronco and it made a huge difference in drivability. I didn't take it off road, but it behaved so much better in town. I knew it was over carbed and out of tune, but didn't realize how much. I needed to use less clutch with the 2100 if that makes sense. The edelbrock 1411 (750cfm) is kinda boggy on it.

Soon as it warms up a little (its 25f) I'll get to work on my fuel pump bracket fabrication which means grinder, my little card table, and the old skid plate. In my head I'm thinking I'll cut a section out of one side of it, leaving 2 of the 4 bolt holes in and cutting down until it stops curving. I'll bolt it on the front side of the gas tank using the center two bolts and put it on backwards from the way it would normally sit so the curved part curves forward away from the tank. I'm thinking that curve will kinda shield the pump since I'll mount it above it. I dunno, it makes sense in my head, but we'll see how everything measures up. I'm only worried about clearance from the rear diff.

 

[Doosenberry]

Yesterday was beautiful out. Probably high 40's with lots of sunshine. Much better than 25 with clouds and rain.

I got the fuel system completed. Made my bracket, installed the pump and filters, and finalized the routing for the fuel line. I will say that this master kit is less than complete. Fortunately, I've been able to order items on the days I work, so they're here when I'm ready to wrench.

I just need to finish out the wiring and it should be up and running today. Pretty excited.

 

[Doosenberry]

Got it wired and running yesterday. Had to make a couple adjustments to the EFI, but its smooth now. I took it for a spin and nearly ran out of gas. I had only put about 4 gallons in it using a gas can after I got the new tank in, so after priming the 20 feet of line, running it over to the exhaust shop and back, letting it idle quite a while after starting up the sniper, and the short maiden voyage of 3-4 miles I guess it was either nearly empty or the pickup couldn't reach what little was left.

I put in a gallon of gas from my little gas can today and it fired up fine. I took it over to the gas station and 70ish bucks later I have a full tank with no leaks. And people make fun of my ugly, old civic. 200 miles of city driving in that thing costs me about 18 bucks. We'll see what this Bronco can achieve in its current form. I've never filled it up all the way since owning it, because the filler hose leaked and its not a dd.

I still need to do some final touches like taking a blow drier to all my shrink tubing and put the wiring into some loom. I left all of my fuel lines a little long, so I'll have to go back and trim them a little once I'm 1000% sure I like where they are. Its kinda hard to go back if they're too short. I also need to put a hole in the firewall to run the cable for the sniper's lcd screen.




Some initial thoughts on the sniper.

Doesn't start any easier than my edelbrock 750, but it was a quick starter to begin with, that was never an issue. If the Bronco sits a long time (3-4 days at least) I expect the sniper to start better since the electric pump does a nice prime first. After sitting a while the carb needed a few cranks to bring gas to the bowls.

The injectors are loud. It almost sounds like some chattering lifters, but it never goes away.

The fuel pump is WAY loud... when you're almost out of gas. Once I got gas it was much quiter. Its still noticeable, but it was crying bloody murder without gas. I should have realized that sooner though. I used to have a 65 Coronet that had an electric pump and a non-functional fuel gauge. The only time I ever heard it make noise was when I only had a couple gallons left. I ran it out of gas once and the closer to empty the louder it got. If an in-tank pump is quiter than the one on my Bronco then I imagine you wouldn't hear it at all. Its fairly quiet, but you know its there.

Something is pretty noisy in the cab by the firewall. I'm not sure it's the injectors. It may be the fuel pump sending noise down the fuel line as I have it attached to the firewall. I think I'll try insulating the clamps some more and see what that does.

There's not as much fumey smell from the exhaust. That's where my adjustments came in. The afr kept going up to 20 (supposed to be around 13). Once I got things figured out, it was where it needed to be. I still need to run it today and see how the exhaust smells. I'm expecting little to no smell with the right afr. The carb was god awful. My wife would comment that I smelled like gas and all I had done was start the Bronco. I know the carb was way out of tune though. I don't get that when running my F100 with the 2100 on it in good operating condition.

I'm not sure this is something I'd put on my F100 unless I put a big noisy engine/exhaust combo. My F100 is super quiet inside and out in its current form and I don't think I'd like the added noise. It doesn't suffer from most of the things my Bronco does and the only benefit I might see is a little fuel economy and a touch of hp since its just got the 2100 on a stock 302. I do have a 460 for it in pieces in my back room, but that project is on hold indefinitely.




I'm glad I got the bulk of it finished yesterday, its back in the 20's again with no sun a huge wind gusts. The gods blessed me with warmth and sunshine on my days off for once. I'll grab some pics of everything before heading into work tonight.

 

[Doosenberry]

Here's what I came up with for a fuel pump bracket. I cut out a chunk of the old gas tank skid plate, bent the mounting flange, wire wheeled it and painted it black, drilled a couple holes for the pump, mounted the pump, and mounted the whole shebang on the front side of the new skid plate. It was incredibly hard to bend the bottom end of it. If I had a vise I'd take it back out and bend it up a little to help cover the pump a little more, but it'll do. The flange with the bolt holes was pretty easy to bend. I just whacked it a few times with my rubber mallet and it bent to where I wanted it. If I didn't bend the flange then it stuck out too close to the diff for comfort.

 

[Doosenberry]

Out of all the things that are "wrong" with this Bronco, the dirtiness of it is what bothers me the most at the moment. I'm not a clean freak, but looking at this intake really bothers me. If it wasn't sealed up good with no leaks, like it is, I would take it off and scrub the crap out of it. At least the inside of it is pristine. I took the time to remove the old, no longer in use, brackets and "plugs" that the PO had put into the intake. Lots of laziness with those damn plugs. I'll just shove a bolt, screw, or nail in this hose and call it good. Idiots.

I'll eventually take the valve covers off at some point and repaint those. I'm not sure who thought orange was a good idea. I've also toyed around with the idea of pulling another set of covers from the JY, making sure the flanges are nice and straight and taking them over to the guys that powder coated my headers, then swapping them with the ones currently on the engine when they're done. It took them 3 weeks to get my headers back to me, so I'm not really wanting to take the ones on there off and then waiting who knows how long to get them back. It's an idea and it's not a priority.

When I took out the battery tray to put in the "new" one that I cleaned up and painted, I noticed that my inner fender is toast. It's super thin all over in that corner, it's rusty, and has some cracks. I'm assuming someone had a battery that leaked acid all over and ate it away over time. I'll have to replace the whole thing sometime later. For now I just sprayed some black paint over the rust and cracks, so I didn't stare at it the whole time I was working on all of this and lose my mind. lol. The parts list I need from my donor truck (my 75 F150) keeps growing as I find crap. I guess it's good I haven't gotten around to stripping it down of what I need yet and sending it off to the crusher.

After getting the new yellowtop Optima 34/78, that comes with side posts and polarity positions on the opposite sides compared to the old battery I had, I'll have to redo the new cables I have. Yay. My cable to the starter needs to be shortened a little, which wasn't affected by the new battery, I just over estimated the length when I got the new cable made. I'll probably shorten the negative since it'll be a nice straight shot to the block from where it's at, and the positive to the solenoid will need a few more inches at least to make it more comfortable. I'll keep it as a spare as it does reach, but just barely. I mounted the sniper leads to the side posts. I also used the bracket for the vacuum canister on that side to mount my relay and fuse. I had to move it a little and put a couple more screws into it to hold it securely as the the metal around the mount area was thin and cracked around one of the original screw holes. I'll mount my headlight relays there as well. The canister (big soup can lookin' thing) wasn't attached to anything and I'm pretty sure it's for something emissions related that was obviously long gone by the time I got the rig. If anyone needs that canister let me know. I chose not to toss it as it's probably a no longer reproduced part that someone (probably in california) will need. I'm going to see if I can find some covers for the side terminals for some added safety since they're close to that bracket. The battery hold down that I used is made of rubber rather than metal and it's preventing the bracket from getting any closer to the battery side terminals, but I'd like some redundancy there. I could also probably take the bracket back off and shoot it with some plasti dip or some other brand of rubber coating. Making stuff up as I go is starting to get less and less fun for some reason.

 

[Doosenberry]

The exhaust. Definitely doesn't look very elegant, but apparently it works. I mean, the engine runs with it attached, so it's functional, right? Now that the Bronco is running again and I've been underneath it to really get intimate with the exhaust, I'm not sure I 100% like what they did. I'm mainly concerned about the clearance between a few things. It's hard to see it all with the pics I took. On the plus side, I think it sounds awesome. +1 for Magnaflow.