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MACKDDY build thread

hankjr

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May 11, 2013
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Howdy folks. Well here is my long promised build thread...... I never felt I was doing anything special, and really had nothing new to offer, so I kept pushing it off. It seems that the project has the momentum now to get a thread started.

This all started when I was considering to put a v8 in my 2000 jeep TJ.

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That seemed complicated and expensive (so silly of me) so I starting looking for something with a V8. I was in El Paso for work and came across a beauty of a 78.

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They wanted a lot for it and I would still have to ship it to NH. Oh no I say, that will be too expensive.......

I get home from El Paso and go into CL. The ad for this one had just been posted. I called the guy. When he called me back the next am, he had received 35 calls. I jump on it figuring I could flip it if I didn't like it. I wasn't looking for the project, it was looking for me:)

I had my first ride in a bronco in Wyoming in 1974 and have always loved the lines of the Bronco. I had an 88 Eddie Bauer for a while back in the day.

Equipped with a sawzall, grinder, torch, and a buzz box welder I did a ghetto build of a 72 FJ40 in the early 90s. 5 months start to finish including a home built tub and floors. " how much harder can a bronco be I say"

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The basics....
71 Bronco that came out of Alabama
Delivered to me early last April (2013) by a local guy that hauls rust free truck beds and such north. I would like to say the bronco is rust free.....

I have always wanted to do a true body off. Being better equipped and better funded than when I did the FJ, it seemed like a fun project to start. I had three minimum requirements for the build, Holley 4 barrel, hurst 4 on the floor, and headers/dual exhaust.

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I was planning to drive to Colorado in July to see my parents so I wanted to have the body and sheet metal at the media blaster for early July. I pushed real hard to get it all apart. I mostly have to work alone and don't have a huge shop, so I get creative to lift stuff. There was a lot of stuff already yanked off the truck when I got it, but the rest came off really easy, including the body mounts.

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Classic Car Blasting here in NH blasted with crushed glass and zinc phosphate coated.

All the while I'm reading everything I can on this site and the sourcing begins. Engine hoist and stand from pawn shop near Dads house.

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I shopped my way east from Colorado scoring windshield frame and dash from WildBill in Topeka, a top and doors from a kid in Illinois, and then swung by JBG to pick up all the heavy stuff (3.5sl, fenders, floor panels, disc conversion etc)

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I got home and dug into the chassis demo to get it off for blasting. All in all it was in great shape under the heavy tar undercoat.

The stock 302 was seized. By this time I'm onto EFI ( so much for requirement 1). I found a local 97f250 plow truck with a broken front axle and just 60k on the 351w for a song. Out comes the engine.

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I find a nice RUGJ2 top loader and hurst shifter locally!

Over the winter I dig out the EFI and front dress and Gt40 heads from the local pull a part. The harness and ECM goes off to EFIGuy. The engine goes off to builder in Nashua.

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Today, the frame is hanging on a engine stand rotisserie and my wingman and I are painting it this weekend along with the axles etc.

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There is much more to tell, and so many more of you to thank, but here it is so far!

Will post more photos of the build to date, along with the results of the painting event Saturday.

Hank
 

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hankjr

hankjr

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Some more photos that were not on the phone....
 

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hankjr

hankjr

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So wingnut and I painted the frame and undercarriage yesterday. First timers with HVLP.

Wingnut :)

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We wished Eastwood extreme chassis black over Eastwood 2k primer. We ran out of paint with one decent coat on everything. Will hit a second coat in a week or so.

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A bit out of order, but some other recent accomplishments;

My ZF adapter kit arrived late last week. So much for the four on the floor and hurst requirement :-0

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Last weekend I used my neighbors lathe to turn a synchronizer collar for the EFI conversion. It's been years since I turned handles but it came back quick enough.

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I've got enough material for two more. I might try to bang those out today.

My track bar mount holes were egged out. I welded in new bushings based on some good advice I got here

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After cleanup they came out ok

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One of the rear spring perches was pitted. I welded and cleaned up the other day. A PITA place to grind but decent result

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Also used a hole saw to cut out the two front body mounts. Finished pics to follow
 

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hankjr

hankjr

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Aaaaaand just realized this is in tech section. I think build threads should be in chat? Does it matter?
 
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hankjr

hankjr

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Ummmm, didn't think that was kosher? Actually figured since I was only replacing the front two, I didn't want to have to mess around with washers on the other six mounts. Probably wouldnt make that much of a difference, but it seemed like the cleanest way to go.

Hank
 
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hankjr

hankjr

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So while prepping for the second coat of paint, I discovered that the first coat did not stick to the primer at all. It stripped off with a razor blade and looked like VCR tape all over the floor. Obviously a hard kick in the nads. I'm still not sure what the problem was. I emailed Eastwood and got some half assed assumptions that when I clarified the details, they didn't bother to respond.

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Well I had to strip it back to bare metal and start over.

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I got that done mid last week and started priming again. Was very careful with cleaning after each step, more so than last time. Wingnut and I sprayed a second coat of primer Saturday and then I sprayed two coats yesterday. I have a few runs to clean up, but it does look good again.

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Not how I wanted to spend the time, but at least I found out before reassembling the chassis.

Now the big push is one to clean up and organize parts in preparation for a wrench a que I'm hosting the weekend of the 6th/7th. The goal is to get back on rubber by Sunday afternoon.

The engine builder called the other day and the engine is almost ready! Tasker dropped a couple parts off Saturday. One of which is needed to button the engine up.

EFIGuy Garry is wrapping up the harness so that should be here soon.

The next big goal is to have the the sheet metal panels screwed in place and the body back on the chassis by thanksgiving to check for for and gaps etc. Over the winter I will work out the fab stuff (hydroboost, hydraulic clutch, steering column etc.). In the spring I will start the welding and then the paint....

Hank
 

tasker

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VERY impressed! you do nice work and coming out awesome. I need to hang out there more and get some motivation! (and PBR's!)
 
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hankjr

hankjr

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So it's been a few weeks since I've posted. Back on the 6th of this month some of the local guys came over and helped getting the chassis back on rubber. Other than a finicky set of lower ball joints that just wanted to spin, it all went pretty smoothly and we rolled the chassis out that afternoon.

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Since then I've been working on sheet metal and prepping the engine and tranny for install.

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Got the engine and tranny installed this past Sunday

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Also made some extra EFI collars while neighbors lathe was still available.

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And spent some time showing number one daughter how to wrench.

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We found the source off the pulsing brake pedal.

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Phew, a lot has gone on in just a few weeks.

Hank
 

langester

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Looking Good! Looks like you'll be on the road before next summer. You gonna drive it out here so I can see it!
 
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hankjr

hankjr

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Not for next summer. Want to get it done though and yes have it out there for the old man to see. You hunting this weekend? I'm driving up from El Paso Friday. Chores for Dad Saturday but can make time for a Shiner :)

Hank
 

langester

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Not yet I will be the last week in October. I will be working on my Bronco and a trailer for my Dad. If you have a few minutes give me a call. I will make time this go around.
 

.94 OR

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You might show Number One Daughter how to install a cabin air filter in the Escape. My wife had one and the filter would get pretty ugly after 12 months of commuting.
 

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hankjr

hankjr

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So it's been a loooooong and snowy winter. I didn't get much done really as primary job was busy and I got a weekend job as a ski instructor. Well now the snow has melted and I rolled the chassis and body cart out today to do a clean up. I finished roughing in all the brake and fuel lines. I need to figure out the vent line still. I have a little touch up painting to do on he engine so I'm waiting for it to be warm enough for that. Once that's done, I'm going to try to finish up the sheet metal. Drivers floor is roughed in as is both inner fenders and drivers kick panel. Still need to do passenger floor and kick panel and patch the rear corner adapters.
A big thanks to all the good posts and information that I've been ready over the winter. I have most of my technical hurdles at least roughed out in my mind. It's now a matter of execution
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Cheers

Hank
 

tasker

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a true masterpiece!! i cannot wait to see this bad larry rollin!!
 
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