75 Bronco Build

[Jesus_man]

I think your bronco looks great with the hard safari top before you installed the sides... I'd be tempted to see if soft sides could be fashioned to use in inclement weather. I would assume it could be a similar design to the soft hatch you mention.

I am so envious of your talents to make things look so nice. My ideas start out like that, but they look far worse in the end.

[Strike2]

Thanks Jesusmn
It’s no show truck but I do enjoy the build along with just trying just like other garage “builders”. I envy those folks here that have far more technical skills than me, for me I really like cars/trucks with small details that make them one offs and not mass produced.

I’m not sure how to put links off other sites but on pirate4x4 I take inspiration to do a better job fabricating by meiser, figjam and manche. I wish I was a better welder it always seems like your bests welds are where no one will ever see them lol

[Strike2]

Since removing the cage I was able to finish welding it up and move on to separating the tub/frame. This proved to be the most frustrating 4 days as have completely ran out of floors space! I guess you just can fit a tub, cage, frame, axles, engine, transmission etc....... in a 2 car garage. I though I could just set the tub off to the side and weld up the frame but my OCD for a clutter free work environment just kicked into HYPERSPACE.
New plan is to put the tub on a trailer and get it out so I can get my sanity/workspace back lol

[Strike2]

The garage world is back spinning in the correct rotation, got the tub relocated and frame is all degreased and ready to finish welding in the 4link brackets, sliders and shock hoops this weekend.

[Jesus_man]

Did I miss where you separated the frame rails? Are you planning to stick with stock width? Always look forward to what you post next! Always a surprise!

[Justin]

I have so much bare frame envy right now. Have been welding under my Bronco and hate lying underneath the rain of molten metal.

[Strike2]

[quote="Jesus_man"]Did I miss where you separated the frame rails? Are you planning to stick with stock width?

While the frame was still attached at the OEM spots I made the front/rear bumpers inorder to square the frame back,the engine cross member needed to be removed just in case I need to add a front sway bar, I will replace the rear cross member but it needed to be relocated to the rear several inches due to the rear stretch. Yes I’m keeping the stock width.
Justin I hear you about welding upside down, I got my fill of that building the XJ I knew the day I bought this I would do everything in my power NOT to weld upside down!! I’m too old for the $#&@ lol

[Strike2]

Spend all day sat welding the link brackets, hoops and sliders and thought I was almost done and then realized I still needed to add 30+ gussets !

[Jesus_man]

That's a lot for a days work!

[Kinder]

Wow, I’m a fan!

[Strike2]

Nothing earth shattering on the build for the last several weeks I've been welding links, axle brackets, trusses hell anything that in steel in the garage I'll throw a bead on it

[Jesus_man]

How about the axle tube to housing?

My welding projects go like that too. I make a list and try to get them all done in one go!

In fact, I am half-heartedly looking for a window AC for my garage so that it is tolerable out there during the hot months.

[Strike2]

Yes to welding the front tube/housing I hope to complete that along with the top truss today and shock brackets etc..................
A/C in the garage would be awesome but I'm sure the wife will veto/laugh at me if I requested one

[Jesus_man]

Cool! My wife seems behind my decision, but then I think of all the moving we do; is it worth it? I can find them for $185-200 for a 10k BTU and that may not be the best, but it seems to be the highest output you can get on 115v. But we have humidity here and often times even a big fan makes little difference.

[ZOSO]

Cool! My wife seems behind my decision, but then I think of all the moving we do; is it worth it? I can find them for $185-200 for a 10k BTU and that may not be the best, but it seems to be the highest output you can get on 115v. But we have humidity here and often times even a big fan makes little difference.

I added a 10kbtu window shaker to my garage about a month ago. It will maintain 80 in 100* weather and my garage faces west and is uninsulated.

[Jesus_man]

I added a 10kbtu window shaker to my garage about a month ago. It will maintain 80 in 100* weather and my garage faces west and is uninsulated.

That is great news! Mine is insulated with the doors having only a double layer of alum. bubble wrap for insulation and they face directly east. And my windows face north so they will most always be in the shade. If I don't pull in a hot vehicle, and I start it in the am, it should remain comfortable to work in!

Back to bronco building..

[landshark]

What do you have the body sitting on?

[Strike2]

I borrowed my neighbors snowmobile trailer which is the perfect width and had no tire fenders.

[landshark]

I borrowed my neighbors snowmobile trailer which is the perfect width and had no tire fenders.

Ah. Thought you might have built a small wooden roller frame. I need one :)

[Strike2]

I borrowed my neighbors snowmobile trailer which is the perfect width and had no tire fenders.

Ah. Thought you might have built a small wooden roller frame. I need one :)

Are you keeping the tub attached to the frame?
if so I have two of these carts that fit on the frame. each cart has 2 stationary wheels and two that swivel.

[Strike2]

I finished welding/cleaning the frame, did 2 coats on both side using Rust-Oleum hammer finish black. I've had great luck using this product plus its not a show truck and I'm sure before its all over I'll have to cut/weld into it and for the $25 investment its cheap and touchup's are easy.
I was only able to work on it Sat and was able to take the tub for spin around the block then organize the garage in order to get the bottom of tub ready for prep and paint. I'm hoping to get this done asap before my custom gas tank arrives from Aero.

[Jesus_man]

Reassembly time!!

[Strike2]

Reassembly time!!

I'm getting close !!!!

The bottom of tub is all prepped and cleaned I was really happy with how "easy" it cleaned up, scrapped off the undercoating some rags/unleaded gas then wash it down with simple green. I then used a wire wheel to remove any loose surface rust, some of the hard to reach parts I used a small portable sand blaster which works so-so and make's a big mess of your garage. For some of sections that I cant reach with a HVLP spray gun I will use some brush on rustoleum paint. For primer I will be using PPG industrial primer finish and then top coating with a satin single stage flat black this worked really well on my XJ and I still have plenty to paint the bottom and floor of the bronco.

I'm hoping to complete this on Sunday as Sat I'm heading to Canon City with a buddy to pick up this 57 CJ5, its not the ideal jeep but my buddy is planning on building a street legal 4 seat buggy and would like the title/key body parts and hopes to eliminate emission testing.

[Strike2]

One of these Bronco tanks doesn't look like the rest, oh its mine

This tank will fit in the back sitting just above the spare tire its only 1-2" above the tailgate, its 36 gallons and once the fuel gauge reads empty I'll still have 5 gallon in reserve. I know its a lot of fuel to carry but like I said I plan on driving this and everyone knows that less pit stops increases you chance of wining the race!!

Now for the bad news, Aero made a mistake on one of the dimension I've spoken with Jake and he confirmed the drawing and they will be making me a new tank to to send out. Like everything I've read about Aero they have great customer support!

[Jesus_man]

I'd like to see that tank unveiled to see what you did. I've put some thought into making mine shorter, but increasing or maintaining the 23+gal.

[Strike2]

I'd like to see that tank unveiled to see what you did. I've put some thought into making mine shorter, but increasing or maintaining the 23+gal.

Here is a picture of my gas tank, its 36 gallons the part that's wrong is it should have a slight "pie" cut out on the sump in order to fit right along the spare tire. This will not work because the tank will stick to far into the driver side wheel well area and not be centered and tight up against the spare tire. The tanks is just 1" above the rear tailgate so this still leaves me room to make a small tool rack just above it and still have plenty of rear view vision.

I sent the fuel pump back to Aero just to make sure it all fits in place, overall I'm happy with quality of the build.

[Jesus_man]

So yours would be in the bed and the sump would extend below deck? That is a lot of capacity and would be nice.

[Strike2]

So yours would be in the bed and the sump would extend below deck? That is a lot of capacity and would be nice.

Yes the tank will sit inside the bed between the rear seat and tailgate, the sump height is just shy of the depth of the spare tire so I will not have to cut the floor out. I made it 47" across so that I can make mounting points off the roll cage, and yea its a lot of fuel but it really didn't take up much cargo room compared to the increase fuel. The tank size/placement was a complete afterthought if you remember my rear tire cage has mounts for 2 - 5 gallon tanks which is not necessary now but have no plans on making other one at this time.

[Strike2]

Not much of an update this week, but I was able to primer/paint underneath the tube, the semi black water based paint I used was from 2011 and man was it chunky! it took about 30 filter to strain 1-1/2 quarts, but was able to apply several coats. On the new inner rear flares tubes I had to apply paint with a brush and them use seam seal to insure there was no bare metal exposure to start rusting, I then made 2.5" wheel well panels to fully enclose the openings. Once I have a few shake down runs I may spray undercoating on them.

[dbasile]

It was great to meet you the other day. Just checked your build out, WOW it looks awesome! Look like lots of time and skills put into your tide. Keep up the good work. Once it done I would like the chance to go wheeling with you.