Pebbles: 1 Family Mostly Stock 68 Build

chuckyb · Jan 29, 2018

Nearing end of tear-down

Getting down to the bare frame. Coil springs, front axle housing and radius arms have been removed. Not much left of the coil cups and not sure if radius arms will be salvageable. I’ve learned that it’s best to get all the nuts and bolts loose prior to trying to raise the frame and remove the axle housings. I have a loaner slide hammer and soaking the rear axles to try to get them free prior to removing the rear end assembly. Once the rear assembly is removed, the frame should be ready for a chemical dip. Looking forward to attaching shiny parts.

chuckyb · Feb 1, 2018

Finally at the body shop and on the rotisserie

My tub and all of the other sheet metal original and repro are now at the body shop. The tub and front clip are on a rotisserie as pictured and will soon be moved to a jig. The baking and blasting of the factory sheet metal has revealed all. Note the pinholes in the quarter / tail light close-up.

The really good news is that some of my sheet metal that I thought couldn’t be salavaged will be, which should result in better fitment in the end. When she is restored all of the factory exterior body panels will be used. Actually, there is one exception to that as I am opting to use a 73 windshield frame so I can run OEM electric wipers. That said, every floor panel, cowl panel, door posts and inner quarters will be replaced. I have purchased the Dynacorn upper inner / lower outer quarter assemblies. These will be cut and the upper inners will be grafted to the factory outer quarters.

After almost 18 years, I am happy to have this chapter of the restoration begin.

Crawdad · Feb 1, 2018

Dang!!!! You got ur hands full. Will you be applying something to prevent any flash rust? That baked process looks pretty interesting.

sprdv1 · Feb 1, 2018

congrats man, I know it never happens fast enough for us

chuckyb said:
My tub and all of the other sheet metal original and repro are now at the body shop. The tub and front clip are on a rotisserie as pictured and will soon be moved to a jig. The baking and blasting of the factory sheet metal has revealed all. Note the pinholes in the quarter / tail light close-up.

The really good news is that some of my sheet metal that I thought couldn’t be salavaged will be, which should result in better fitment in the end. When she is restored all of the factory exterior body panels will be used. Actually, there is one exception to that as I am opting to use a 73 windshield frame so I can run OEM electric wipers. That said, every floor panel, cowl panel, door posts and inner quarters will be replaced. I have purchased the Dynacorn upper inner / lower outer quarter assemblies. These will be cut and the upper inners will be grafted to the factory outer quarters.

After almost 18 years, I am happy to have this chapter of the restoration begin.

chuckyb · Feb 1, 2018

Crawdad said:
Dang!!!! You got ur hands full. Will you be applying something to prevent any flash rust? That baked process looks pretty interesting.

Hi Matt, I think it’s got something on it already, it felt a bit oily to the touch. Everything will be seam sealed under and over and hollow parts like the windshield frame will be channel coated with POR-15. The goal is no more rust ever!

Crawdad · Feb 1, 2018

Did the guys who baked it give you any input as to what they applied after baking? Maybe it’s me but I think I’d want to get any and all oil off of it as it may ruin paint adhesion and or sealant adhesion. Maybe someone can chime in and correct me.

904Bronco · Feb 1, 2018

I just read through your thread, 4 generations working on and enjoying this Bronco.
I don't know how you Guys and Gals in the Midwest/East coast deal with so much rust?
I probably would have walked... We are spoiled living on the Left coast and dealing with minor rust.
Keep up the good work, it takes time and money to do it right. Every little completed job is a step towards the end result. Which is driving and enjoying, sharing it with Family.

chuckyb · Feb 2, 2018

Crawdad said:
Did the guys who baked it give you any input as to what they applied after baking? Maybe it’s me but I think I’d want to get any and all oil off of it as it may ruin paint adhesion and or sealant adhesion. Maybe someone can chime in and correct me.

She is no doubt in good hands but I’ll check and make sure.

chuckyb · Feb 2, 2018

904Bronco said:
I just read through your thread, 4 generations working on and enjoying this Bronco.
I don't know how you Guys and Gals in the Midwest/East coast deal with so much rust?
I probably would have walked... We are spoiled living on the Left coast and dealing with minor rust.
Keep up the good work, it takes time and money to do it right. Every little completed job is a step towards the end result. Which is driving and enjoying, sharing it with Family.

It’s all about the memories! I know it would make my Grandpa happy and the grandfather / father / son time is awesome. I brought both my son and daughter to the body shop and it was a great experience! We wish our old machines weren’t so rusty here on the east coast...

rydog1130 · Feb 4, 2018

cool man! can't wait to see it done!

chuckyb · Mar 7, 2018

Progress at the body shop and with the frame

Here are the most recent pics from the body shop. Also, here are a couple of the bare frame on the way to get dipped from two weeks ago. I have a welder lined up to help with the frame repairs once I get it back. Once the frame is repaired, it will be on its way to get powder coated.

chuckyb · Mar 7, 2018

More pictures of body work in progress

I visited the body shop today, dropped off some beer and took some more pictures. The copper color is weld-thru primer. Parts are being fitted and will be disassembled, then primed and put back together.

The black driver's door front post is an NOS piece and fit with less work than the aftermarket one on the passenger side. The door hinges seen are ones laying around at the shop. I have the removable SS door hinges which will be used for the build.

I learned that the new rocker panels, which are the OEM kind from the vendors, are consistently 3/16" too long. They will need to be removed and cut down to make the gaps better. The new Dynacorn inner upper / lower outer quarter panels are being "scabbed" - only the inner upper part will be used and the OEM outers will be salvaged. The original driver fender may not be able to be used due to rot on the top edge. I am hoping it can be. If it is, all OEM exterior facing sheet metal will be reused with the exception of the rockers and the windshield.

The body work is happening fast! My main concern now is getting the frame ready and rolling so it is ready in time.

sprdv1 · Mar 8, 2018

Nice Chuck... Coming along

904Bronco · Mar 8, 2018

Be sure to tell the blaster/powdercoat shop to protect the vin stamped on the frame during the process. Or else it will disappear...

Very nice work so far

Crawdad · Mar 8, 2018

904Bronco said:
Be sure to tell the blaster/powdercoat shop to protect the vin stamped on the frame during the process. Or else it will disappear...

Very nice work so far

I agree, they should have hi-temp tape. Make sure they don’t sandblast the crap out of the vin as well. A light sandblast should be enough for ur vin. You don’t want them to blast away ur vin.

I may need your body man, looks like he has a few Broncos he’s doin.

rydog1130 · Mar 8, 2018

looks good man....you’re making great progress and it’ll be no time before it’s back on the road!!

chuckyb · Mar 15, 2018

Prep for zinc plating

After taking the winter off, I have fired up the compressor and blaster. Working to get all the parts clean and rust free so I can bring them all to the zinc plating place. They normally do much larger jobs and there is a minimum charge so I want to bring everything at once.

It makes me nervous taking everything out of the labeled bags and throwing it all in a bin so I am taking lots of pictures.

rydog1130 · Mar 17, 2018

That’s quite the ambition I still have bags of bolts labeled laying around! It was just easier buying new stuff instead of having it cleaned and replated. You’ll have a lick creek custom build the way your going!

chuckyb · Mar 26, 2018

Frame - Acid Bath and Blast

The frame and radius arms have now been dipped for several days and blasted. I have transported the frame to the body shop. My body man wants to take measurements to ensure no surprise misalignment. It will get some repair for front and rear body mount locations and upper rear shock mounts.

Once the repairs are made, it goes back to the blaster to get a quick re-dip and blast to get rid of flash rust. Threads and VINs will get protected / masked and it will be powder coated black.

chuckyb · Mar 26, 2018

Panel and Door Alignment, Tailgate post repair

Body work seems to be moving along nicely. Rocker panels are trimmed to fit and there seems to be excellent attention to getting all of the gaps at the doors and body panels just right. The Dynacorn TG posts will not be fully installed. Instead, originals will be salvaged and just the back-facing panels toward the taillights have been scabbed off the Dynacorn pieces and used to repair the OEMs.

I’m really happy with the attention to detail and the way everything is fitting together.

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