What have you done to your Bronco today? (v.2)

[Jesus_man]

Nice work Chad! Gives me some idea of what to expect on mine. Trying to decide what to do with the fuel tank still if I stretch the wheelbase more. I'd like to stretch the body a little a-la-kirk, but more interested in pushing the axle back and that may not allow me to use any type of standard tank. I'm thinking I want to make the inner wells larger by cutting them and pushing the rear half back and patching it. That would interfere with my filler neck. But maybe I could then use the AUX hole for a custom tank under the body just forward of the rear axle. My fear is downtime. I don't want this to be a 6 month project.

[Gunnibronco]

Thanks JD. There was more room than I expected.

The "rock crawler" I was looking at a month or so ago had its axle pushed back 6". The axle was set just below the rear frame crossmember. He was running a fuel cell in the bed of the Bronco. The fuel cell (and lack of hard top & doors) were the main reason I didn't want the whole truck. I still need the rear cargo area for my dogs, hunting, etc.

I was hoping to push the axle back 3" or 4", but I think even the stock tank would have been in the way. That is why I don't feel bad jumping to my larger tank. I think you are right, you'll either have to get very creative, or resort to a bed mounted fuel tank. If I ever get to the point my truck is towed everywhere, and strictly a crawler toy, then I'll consider the fuel cell.

[Jesus_man]

I am going to avoid a fuel cell in the passenger compartment at all costs. I just don't want to give up the space and want the ability to take my family and some gear camping in it. So extend the frame/body a few inches, push the rear axle back a few and that's where I'd like to be.

Although "the family" would be much more comfortable in something like this:
http://www.colorado4x4.org/vbb/showthre ... ost2200726

[Justin]

I've been watching that build, it's a sweet rig for sure.

[Gunnibronco]

Wired the aux tank transfer pump. I won't have a fuel gauge on the aux tank, but I'm just using it as storage. You can hear the difference in the pump when it runs dry. I'll get the gauge working when I rewire the truck.

Can't wait till the new tank arrives!

I also noticed that the section of rear fuel neck I cut off, looks surprisingly like the rubber hose from the aux tank to filler neck. I'm thinking I might just see if Napa or Carquest has a similar fuel filler hose. If they do, I'll probably not weld the lower elbow back on.

Dry fit the 70mm MAF I've had sitting around for 8 or 10 months. Should fit in easily. Hopefully its a plug-n-play just like I read. Doubt it will make any difference.

Wasted a bunch of time working on my house, with no real progress.

[landshark]

Since project "elk carcass"is on hold a few days, I decided to mount the duff rear shock mounts I picked up from Justin. Gained about an inch and a half so the shocks should be happier.

[Rox Crusher]

I finished installing a mount for the Baumann transmission controller.

Credit for the idea goes to 76fordBronco and thanks for helping build it goes to Gregg !

The ECC and the amp for the stereo sit on the transmission hump behind it for easy access.

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[Moab Mike]

Lookin' good!

[Gunnibronco]

Finished up my 70mm MAF upgrade. Oddly enough the inlets and outlets were the same size as the 55mm MAF. So I just made a quick bracket and added a screen in front of the new MAF, and it pretty much bolted right in place of the 55mm MAF.

Since I wanted to run it and check the new MAF, I hooked the aux transfer pump up to the accumulator, and sent the return line to the aux tank. I also pulled the main tank LP pump, since it had to be relocated for the new tank, anyways. It was pretty quick and easy. Truck fired right up. The new MAF worked fine, sitting in the garage. I didn't pull the truck out, my exhaust is hanging loose for the main tank install. Gave it a few revs and it sounds a little different, but also the hood was open. You can really hear it suck air.

[Jesus_man]

Mine whistles at idle. Kinda annoying!

My dad said he started it up and ran it around a bit. Says he hooks up the battery and it fires right up every time!

[Gunnibronco]

Since my new tank is being built & shipped, I'm on hold for that project.

I bought a roll cage kit last year, and gave away my old roll cage earlier this summer. With hunting season coming up, I had to get a cage (and 3 point seat belts) back into the truck. So I started on that today.

Stripped out my seats & center console & storage boxes. Also unbolted the top and folded the windshield down to remove the dash pad.

I got the 2 main hoops in and tacked to the floor plates, front & rear. I went to three hardware stores and the only store that carried carbide hole saws had 1 size missing from their stock. Guess what size that was? 1.75", the size I need. Won't have it till Thursday at the earliest.

How many bi metal saws am I going to need to make about 14 cuts in .120 wall DOM? I'll probably go back and buy one, and see how it cuts. I have time tomorrow to keep working on this, but I don't want to waste a bunch of money destroying hole saws.

[landshark]

Project Elk carcass is complete!

I will have to take some photos of the finished product all painted and pretty

[crawlercreations]

Since my new tank is being built & shipped, I'm on hold for that project.

I bought a roll cage kit last year, and gave away my old roll cage earlier this summer. With hunting season coming up, I had to get a cage (and 3 point seat belts) back into the truck. So I started on that today.

Stripped out my seats & center console & storage boxes. Also unbolted the top and folded the windshield down to remove the dash pad.

I got the 2 main hoops in and tacked to the floor plates, front & rear. I went to three hardware stores and the only store that carried carbide hole saws had 1 size missing from their stock. Guess what size that was? 1.75", the size I need. Won't have it till Thursday at the earliest.

How many bi metal saws am I going to need to make about 14 cuts in .120 wall DOM? I'll probably go back and buy one, and see how it cuts. I have time tomorrow to keep working on this, but I don't want to waste a bunch of money destroying hole saws.

Are you using a tubing notcher? If so you will be perfectly fine with 1 name brand bimetal hole saw. All I use is bimetal hole saws and I get at least 70 notches out of them, probably more. Lots of good cutting oil and slow turning speed make them last a long time. The Milwaukee ice bimetal hole saws are my favorite as they seem to be the fastest and last the longest. Your mileage may vary depending on method used to notch.

[Gunnibronco]

Yes I have a tubing notcher, that is good news, I can keep moving forward tomorrow.

Thanks

[Jesus_man]

Chris - that's a nice rack! LOL! But what you bagged looks a little more like roadkill...

[Rox Crusher]

Chris - that's a nice rack! LOL! But what you bagged looks a little more like roadkill...

That's his roadkill rack for when he visits MT.

http://www.abcfoxmontana.com/story/2366 ... kill-rules

[Gunnibronco]

Ended yesterday looking like this.

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Today I installed the front crossmember, and pieces running horizontal above the rear wheel wells. So the cage is mostly tacked together.

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I have cut the 2 upper piece above the drivers & passanger's head, but haven't attached them. I'll fit them when I take the cage out at my friend's house and use his 220v mig to weld it up for real.

P1010949.JPG

I've also notched 6 short struts that will reinforce the center vertical pillar/crossmember/hoop instersection.

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I have 2 longer pieces of DOM left. I think I'm going to use them between the center & rear roof crossmembers, like the 2 above the driver & passenger seats. The kit would have them installed across the truck behind the front seats and at the rear of the truck. I will install removeable crossmembers at a later date. But those will be easy to install later, without removing the cage.

[Jesus_man]

Nicely done Chad. With your extra pieces, maybe make an "X" pattern for the back?

As for the overhead bars, I put a bend in mine so that it would shed the water better when I have my soft-top on. And, I love my CB between those two bars too.

I also have a hi-lift mount built into the rear which keeps it out of the way, but easily accessible.

[Gunnibronco]

Nicely done Chad. With your extra pieces, maybe make an "X" pattern for the back?

Thanks

As for the overhead bars, I put a bend in mine so that it would shed the water better when I have my soft-top on. And, I love my CB between those two bars too.

I also have a hi-lift mount built into the rear which keeps it out of the way, but easily accessible.

I can't bend the DOM, so I won't have a "pitched" soft top. It will be better than the old cage which didn't have anything above the driver & passenger, when it rained my bikini top would just sag down and fill with water. I got pretty good at pushing water out, without it ending up in my lap.

I thought about the X across the rear, I need to measure and see if they are long enough.

I had my Hi Lift bolted to the diagonal rear upright on my old cage. I want to bolt it on the horizontal bar abve the rear wheel well. I also have always carried a shovel & axe & I'd like to mount my come-a-long too.

[Gunnibronco]

I didn't get much done last night. But I did get my pbrake pedal put back in. I just had to cut about 1/2" off the pedal. I have something else "cool" planned for the pbrake assembly, maybe I can get it done with my new dash board, right now it just has to work for hunting season.

I also drilled holes in the middle vertical legs for the new 3 point belts I have. I'm using these to install the belts:
http://www.ruffstuffspecialties.com/catalog/FIXTHR.html

I measured the 2 extra crossbars I have. They are too short to make an X across the upper rear part of the cage. I think I'll just save the 2 pieces I have, and use them for crossmembers as designed. I'll order 2 longer pieces to make the X crossmember. I don't think I'm going to get this painted this winter, so next spring I"ll pull it to paint it (and my redesigned dash at the same time). I'll add the crossmembers & X at that time.

[hockeydad4-22]

YEEEEEEESSSS!!!!!!

pulled her out of the garage for the first time in over 3 month and took a few joyous grin filled trips around the block this evening.

Need a new upper radiator hose and I am not 100% confident in the power steering pump

Oh yeah, and a complete exhaust, but for a short shakedown test run.... she ran awesome

I guess I will have to open a utube account to show the video.... Oh well, you guys will just have to wait till you can check her out in person

(Yeah, I posted this in the build thread , I am pretty damn pumped)

[Gunnibronco]

Congrats, that's sweet.

[Colorado75bronc]

Awesome glad to hear its moving under its own power, now we just need that video! :)

[Justin]

Nice!

[Gunnibronco]

Drove over to my friend's house, pulled my hard top & cage out. It's set on his floor and ready to be welded. We played a little and set up his welder on some scrap tubing. I have to say, after tack welding the cage together with my 135 Lincoln, I was starting to second guess my welding. Its not rated for the .120 wall tubing I'm working with, but my results were embarrassing. A few runs with the real welder, and my confidence is restored. I need a real welder.

Last night I put my back seat and ammo can storage containers back in my truck. I figured a quick hi-lift mount and axe/shovel mount. With the new cage there is more room, and I'm going to plan on moving the ammo cans to allow the rear crossmember to be fitted, and also move the hi-lift to the rear across the truck. But that will have to wait, probably until spring. Hunting, work, snowboarding, house remodel will take priority for a while. Soon it'll be too damn cold in my garage to work anyways.

[Gunnibronco]

Spent the day working on the Battlement Fab cage kit. I had to grind off all my crappy tack welds and retack the joints along the way. Got everything welded in, and started cleaning up the welds. I'm not consistent enough to leave them undressed. A few came out looking real nice, but some didn't look great. I found the hardest part was getting positioned to weld around the tubing. By the end I was doing pretty good. Sorry, no pics, forgot the camera. I'll post up pics tomorrow night. Hopefully it will be rattle can painted & installed.

Still waiting on my replacement gas tank.

[Gunnibronco]

Done welding, grinding and preping.

I have a bunch of gray paint mixed from painting my rims & ammo cans. I rembered some of it was direct to metal, so its getting painted with a medium gray. Should be done and drying by this evening.

Left the camera at my friends house, just grabbing my paint mask and lunch. I'll have pics up this evening.

[Gunnibronco]

Obligatory Bronco porn:

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Here it is before paint:

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After paint, bad light, its darker than the pic

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I wish all my welds looked like these

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[Rox Crusher]

Niiiiiiice !

[Peter Werlin]

That looks really good. Love your pickup! I took mine out for coffee and then tried to find the bolts for the rear seat belts That I took out in 1993.! I've been looking for them all summer! Then I saw an all original 1965 mustang and figured they might be the same and they are! My friend would not let me pilfer his so he contacted a friend who restores old mustangs and he has a set! Problem solved...now I'll probably stumble across the originals tomorrow! Peter