This past weekend I picked up a straight and rust free tailgate for my 79 for only a 100 bucks. Its complete with the window glass and all.

I've been playing around with dash designs for the last few days.

I've accumulated a very nice set of gauges, a Centech harness, an extra dash board, and a new DOM roll cage kit from Battlement Fab. My goal is to build a new dashboard, remove my old dash & cage, rewire the truck & install a new dash, and cage this winter.

My gauges are these Auto Meter gauges, 2x 5".
http://www.summitracing.com/parts/atm-1204/overview/

I think I've settled on a dash design. I'm going to keep using the big tach I have mounted to my steering column. I don't think I'd be happy trying to watch that little tach on a Bronco. I don't like that Bronco gauges are so far off the line of site of the driver, but without major surgery, that is not going to change.

On the right side, I'm going to move the glove box to the left, so it is usable with a roll cage, and move the stock speaker "grill" behind the roll cage leg.

On the left, I'm going to use the speaker grill from my original dash, and put it behind the left leg of the cage. I can fit a 5.25" speaker behind the grills, and the hole pattern matches. Here is a pic of design I've drempt up. It is for everything to the left of the relocated glove box.

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The speaker grills and glove box will be welded back into the dash, in their new locations. But for the gauges & controls, I'm going to end up cutting most the original dash face off.

I'm going to build 2 panels, one for the left side of the steering column to house the multi gauge, and one large panel for the right side of the column, that will hold the speedo, ignition, wiper, light, heat, air compressor controls, cb, and a lighter (my truck didn't come with one). The panels will allow for easy access to wires & stuff, and if I change things around (as I'm prone to do), I just have to cut a new face plate, not redo the whole dash. I'll probably pop rivet the gauge panels to the skeletonized dash board. I'm going to use the glove box to hold the EFI ECU & relays, and the fuse panel. I'm going to reuse the stock ignition, wiper (ordered an intermittant set up), head light, and heater controls. The CB will be in the spot where the stock radio was. My radio is in a Toughy center console.

This gauge set has an electronic speedo with VSS, so it will double as a VSS for the ECU, and allow me to have a speedo that is accurate. Right now I'm 25%+ off, with gear & tire size changes from stock. I also like its retro design and it seems to fit the Bronco nicely.

I also patched the small holes in my "new" main tank. I'm going to replace the main tank with this redone one. The old one has a serious patch in a spot regularly covered in fuel. I had to do an emergency/gorilla patch this spring after a 15 year old return line fitting cracked its solder. This new tank has 2 small holes only at the very top of the tank, and they are rock solid now. Since the new gauge uses a new sending unit, it only makes sense to replace the tank when I pull the sending unit.

Yesterday I took my first real steps towards my new dash.

I had to pound out/straighten my "new" dash where some one had really overtightened the dash/windshield knobs. I mean really over tightened. I had to cut the back side of the dash & bend it back out of the way so I could get a hammer & dolly behind the right side. The left wasn't as badly dented, but it took some work. I may weld an extra plate over the 2 holes. The dash won't look good without some filler & sanding, and I think the first time the windshield was bolted down, it would crack the filler.

I also got the old glove box & speaker grill out of the "new" dash, along with the sections of the dash where the speedo, cb, and controls will go.

Today after hitting the slopes for the first time this year, I pulled my Bronco in the garage and cut the speaker grill out of it. My air tools are struggling in the 30* garage, I'm going to have to fire up heat the next time I work.

So now I'm ready to finish fitting and weld up the new dash. After the glove box & speaker grills are welded back in, I'll build the panels to house the gauges, etc.

Also, when I pulled up to my friend's house to go snowboarding, there was a real sweet Bronco sitting there, probably on 33's. Its his neighbor's, a quick look & I saw some home fab'd long radius arms. I'm looking forward to meeting up with him soon.

Here are some pics of everything just layed out loosely.

Sweet man, looks good, did you snap a picture of his bronco?

Thanks,

I did not get a pic, I will next weekend. It was really beautiful, covered in about 12" of snow.

Chad

Nice work, Chad. Might have to send you out a dash. LOL

Not today, but in the last few days...

Installed the gas shocks on the rear lift gate. Man, what a difference. Not only am I able to throw away the prop stick I was using to keep from bashing my brains in, but the force exerted by them when the lift gate is closed seems to have eliminated much of the rattle I was hearing going over bumps.

Second thing I did was a two part installation of Corbeau seats. Still not done yet. Day one was just getting them mounted up and seeing what issues I might run in to. There were many. Day two was putting the carpet back down and remounting the seats. With the low profile of the seats and mounts I can actually see traffic lights again.

Third thing was installing retractable lap belts in the front and moving the non-retractable belts to the back seat. I'm 90% complete on being able to haul the family around with me.

I've thought about a new dash for a long time. I'm pretty excited to get at it. Lots of things to keep track of. I'm sure I'll forget a few along the way & have to do some emergency rethinking. Won't know till I try to install everything for real.

My truck was a rattle trap, and putting the shocks on the gate helped a ton. Putting the gate "locator" post back on, made even more. I've spent most my 15 years tracking down & fixing the next loudest rattle or bang (body is all misaligned from a minor "roll" by the PO). I've got it pretty good now. An old friend visited recently and made a comment about how quiet my truck was! I think I'm to the point that some attention to the floor and roof with some insulation and carpet/headliner might actually be worth it.

Got the right speaker & glove box welded in.

Looks like there is room for a 12" sub behind that grill?? No? If I ever re-do my dash, I think I'll narrow it so that when I build a new cage, it can tuck in further forward. I saw this done on another bronco and it was done well enough that it took several rides in that bronco before I noticed it.

LOL. A 5.25" speaker will fit, barely. The actual speaker is slightly wider than the grill, and will overhang behind the grill by about .25" each side. It won't sound great, but at least they will be aimed at my ears. I can barely hear my radio running down the highway. I thought about some 5x7 or 4x6, but I figured I'd use what I had.

Cool idea narrowing the dash. There are 2 things I would have liked to do, but I didn't want to build a whole new dash. I would like to move the dash towards the driver a couple inches, to make controls easier to reach. Also I'd like the gauges mounted up higher, but the defrost ducts are right behind the dash. Moving the dash towards the driver would add a couple inches of depth, and might make that possible.

Pretty sweet! Jealous of the snow!

Finally had some time to work on the bronco this weekend. Cut off the rocker on the driver side. Stripped the grill and passenger fender. Going to replace the driver fender.

Since I'm going to have the dash, & heater out of my truck sometime this winter I did some reading about noise/heat dampening. My truck is VERY loud, I have a 10+ year old, semi-mutilated homemade firewall insulator, made from something like this: http://www.summitracing.com/parts/tru-12475/overview/
And that is about it, Herculined tub & bare top w/no headliner.

I think I'm going to cut a firewall protector from the HVAC foil bubble some guys here have used to line the whole tub. Since I don't have carpet, I'm just going to do the inside of the firewall. I will do the whole tub someday, before a vinyl or carpet kit. And I also want to insulate the roof. I'll probably use up the rest of the cotton insulator on the roof, since its less likely to get wet and hold moisture.

I wanted to do a little more to deaden the noise, and found a good recommendation for a product called Second Skin, on CB.com. Its a sound dampner with foil barrier. Less expensive than Dynamat, & supposed to be better, lighter, etc, also made in the USA. Today I received a box of this stuff:
http://store.secondskinaudio.com/damplifier-pro/
I bought a couple boxes of the "B" stock, figured it was the same price as the non blem cheaper stuff. I'm planning on putting this up on the inside of the firewall, and inner quarters, this winter. I may do the top, and tub before insulation/headliner/carpet kit in the long run. But I will probably change trans & tcase before buying a carpet kit. I may not use it up on the Bronco, instead using in my 39 Plymouth.

They shipped quickly, and also have some cool (excuse the pun) heat barriers. I wish I had added a piece of their Thermal Block to the order. My muffler is very close to the floor & it gets pretty hot.

First I was able to get my 100# propane tank set up with about 25' of flex hose. The heater worked really well. Started at 19* and got up to 45* in less than 2 hours. Outside temp was 5*-10*. I'm sure if I had kept it running I could have easily brought the temp up into the 50's. In a Carhart Arctic union suit, it was comfortable to work in the mid 30's. The air tools & my battery welding helmet don't like it though. The helmet is going to live in the house, on the window sill for a few days.

Got a little more done on my dash, before the helmet gave up.

While my Bronco To-Do list is extensive:

Finish up power steering pump install.
Change out radiator.
Measure and / or install driveshaft.
Install the body mount / lift kit. COMPLETED 1/9.
Replace the Front Bushings.
Install the Twin Stick.
Install adjustable track bar.
Install windshield mount rubber weatherstripping for bikini / soft top.
Rust Repair.
Install front fender flares.

With an ABSOLUTELY AWESOME assist by Corey (Colorado75bronc) last night, we were able to install the new body mounts and the 1 inch lift in a little less than three hours I think. No doubt I would have made a mess of it if had I tried to do it on my own. The potential for the body to fall off of the frame -- had I removed all of the 8 bolts at the same time and lifted the vehicle from one side -- sounded just awful! Corey, as always, brought his significant expertise (and a really heavy tool bag) to the task and made short order of the work. Now my tires clear at least a little better, though trimming fenders seems to be in my near future.

I've read a few threads on CB.com about firewall insulators. The stock ones & replacements tend to break easily. I tore mine out years ago. I used a foil backed "jute" product like the Summit like above, and cut my own out, lined the firewall, and bottom of the cowl with it. I'm sure it does something, but with a herculined floor, its hard to tell. I can feel the heat from my muffler through the bed floor. I wouldn't use this stuff where it can get wet, its made of cotton like material. So I'm not going to use it on the firewall again. My cowl leaks some, and a leaky heater core would also soak it. I'm going to use a foil/bubble insulation made for HVAC (heating ducts). Its cheap, available at Home Depot, etc, and it won't retain water. Some of the guys here have lined their whole tub with the stuff, before carpeting, and had good results. I'll look for a link here, I know there is a thread somewhere.

The Secondskin Damplifier that I bought is not really a heat insulator. It is more of a sound deadener, very like Dyanmat. It does have a foil backing so it will help with some heat. I'm going to line the inside of the firewall with this stuff, then put the foil/bubble on over it.

I haven't done any of this yet, so I can't comment on the products. I'm going to rewire & put a new wire harness in, and I'm going to do it then. I read good reviews on Second Skin on CB.com, its cheaper than Dynamat, but according to some better. For what its worth. I have no experience with any stuff like Dynamat.

Second skin does sell heat insulators, one like the Summit product above- Heatwave Pro, and another that is a ridged board (and very expensive)- Thermal Block. I wish I had ordered a small piece of the Thermal Block to put between my muffler & floor. Oh well, next time.

Here it is:
http://coloradoclassicbroncos.com/viewt ... lit=carpet

Kept plugging away at my dashboard. Finished welding up the left speaker, and welded a bunch of extra holes shut.

I dropped of my templates at a sheet metal shop. They're going to cut the panels & the 4-5/8 holes for the main gauges. I'll cut the rest of the holes for the switches & CB.

I got a package from Summit Racing with a fuel sender for the new gauges. I'll have to cut it into the top of the tank. Also got a new regulator for my welder (mine isn't working right) and a big set of 24" vice grips.

Mailman brought a sweet Bronco calander, too.

I'd like to borrow an ignition & headlight switch, and heater controls. I know its a long shot, but it would be nice to have spare set to build my new dash. If anyone has some lying around.

This morning was a good news/bad news situation. Temps fell to -30*, and the truck fired right up this morning (good news- love my EFI!). The transmission is always stiff to shift when its cold, this morning was no different. But when I shifted into reverse the shifter pulled out of the transmission. Most likely, it just "unlocked" itself from the trans, I need to pull the shifter boot off and look. Keeping my fingers crossed it didn't crack the top of the trans. I might end up with a ZF much sooner than I thought.

Since it warmed up to 12* and I had a few minutes, I decided to see what had gone wrong, with my gear shift. Not what I expected.

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I actually had an extra one and had it fixed in 15 minutes. Might buy a Powerball ticket today.

Much nicer than a busted shift fork. Buy me a ticket while you're cashing in on the luck.

Ever see a ZF in a 39 Plymouth?

P1010746.JPG

Thanks Zach, for picking up my Craigslist score, and then even finding a way to get it delivered to my house!!

Now for an Atlas.........

All in a day's work. Glad the guys made it out there with the transmission safe and sound. And hope you didn't have to go too far out of your way to pick it up.

They brought it right to my house and helped load it into the old parts Plymouth.

Thanks again!

Nice score man, I'll have to post the pics of my adjustable coil buckets and trac bar all on, just had a few hectic couple weeks, had to put a new clutch in the bronco, also ended up rebuilding my spare np435 and putting it in, and also decided to remove the gear banger because this newused trans shifts so well with the stock style shifter, and since I'm going to be swapping a 4bt and possibly nv5600 6spd within the next 6months to a year so I might as well sell off the wild horses gear banger if anybody is interested

Picked up my dash gauge panels.

Lots more work to be done, but the glove box door is fitted, speakers fit- barely, and I've temped up a fuse & relay panel. I stole this idea from Zoso, somewhere he posted up a pic of his fuses in his Big Bronco. Thanks.

The extra relays will be for headlights, horn on Centech kit, & my driver seat power- I've never hooked it up since I swapped the seats. I ordered the 4x fuse panel from our Carquest, thinking I was getting the same panel as the RJM harness, but it isn't, oh well. I think 4 extras will be fine for a while. I don't have lots of extra stuff to power. The panel looks small in the pic, but it actually is the same width & height of the glove box opening.

I welded a "custom bent" washer to each windshield tie down hole to cover the damaged areas & reinforce it. It might be a trick to make it look real good, but its hidden behind the roll cage. I think with a little more work and some filler & sanding I can make it look ok.
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