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Floor Pan and Other Half Done Metal Work

rydog1130

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Since you are replacing the kick panels, now is the time to drop your floor pan in. It will be easier to get in there with the kick panels out. Your new kick panels will attach to your inner rockers on your new floor pan. Id also put your new body bushings in so everything is at the correct height. Looking good keep at it!
 
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Jamie Chriss

Jamie Chriss

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Feb 28, 2015
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576
I have a sheet metal replacement addiction! Putting in the platform tomorrow, hopping to start actually making some progress. My Bronco has shrunk so much my wife is catching on this isn't your basic fix a few panels, paint and drive project.
 

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Jamie Chriss

Jamie Chriss

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Made some positive progress today! Complete platform is in, fit is really good.
 

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USMC-72BRONCO

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Apr 12, 2017
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Loc.
Oceanside
Jaime i'm by no means a bronco expert just getting ready to get started on mine. I live in Oceanside and if you ever need an extra set of hands let me know your right down the way. Also following your thread i need to replace the driver and passenger panels soon. Great job its coming along
 

tk1218

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Nov 23, 2008
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Flower Mound
That bronco is in tough shape. if the welder keeps blowing through the metal you most likely will need to replace the metal as its too thin, but i guess you know this by now.
 
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Jamie Chriss

Jamie Chriss

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Feb 28, 2015
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USMC, thanks! I have learned allot of lessons working on this truck so when it comes time to helping you please ask. As for blowing through sheet metal TK, that was a really hard lesson learned! I spent a month removing bondo and rust off my bed to find 100 small rust holes you could actually see light through, that is when I decided to start replacing all the sheet metal. Also my welding technique is improving, at the beginning I made some extra work for myself. Most of the damage is from PO hitting other cars.. The entire front was pushed in enough that there was an obvious lean to the truck. I am replacing the inner fenders, radiator support along with the stuff in my pictures.
 
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Jamie Chriss

Jamie Chriss

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Feb 28, 2015
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576
Made some progress this weekend. Hindsight I wish I would have done a better job supporting my dash, the two supports I welded on where not square so I had to remove them to get the dash back to the right height two man job for sure to light the dash and square the corners. Anyway having new metal makes the job much easier.
 

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Jamie Chriss

Jamie Chriss

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Feb 28, 2015
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Making progress, the new bed sides are not as deep as the old ones the welding surface may be at best 1/4 inch where the original was more like 1/2 so it doesn't cover the old weld holes... Not sure how I am going to handle this one?
 

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bronkenn

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Yeah them new rear floorpans are definitely stamped a little short on the weld flange, I don't know why they never fixed that. I just clamped the floor to wheel tub together and but welded them, ground them a little and they came out pretty good. Would rather have plug welded but sometimes you have to work with what you got. Keep chipping away. Ken
 

rydog1130

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Making progress, the new bed sides are not as deep as the old ones the welding surface may be at best 1/4 inch where the original was more like 1/2 so it doesn't cover the old weld holes... Not sure how I am going to handle this one?

Get a copper welding spoon from harbor freight and weld all those holes in. Grind them down smooth with a 120 grit flap disc.
 
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Jamie Chriss

Jamie Chriss

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Feb 28, 2015
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Made the decision to replace all the metal windshild frame back! The drivers side was hit hard and everything is pushed to the center of the truck, I spent months going backwards. This is very much uncharted territory for me. My wife is already asking when she can park her car in the garage.. um honey soon, very soon.
 

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rydog1130

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Made the decision to replace all the metal windshild frame back! The drivers side was hit hard and everything is pushed to the center of the truck, I spent months going backwards. This is very much uncharted territory for me. My wife is already asking when she can park her car in the garage.. um honey soon, very soon.

Yup, youre where I was....just make sure you sheet metal screw everything together before you weld it! its not impossible just time consuming! good luck! Even after getting to this point I still had to push and pull things with a body jack to get it all square!

IMG_1525.jpg
 
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Jamie Chriss

Jamie Chriss

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Feb 28, 2015
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576
Rydog, I am putting together the upper quarter panels, what was first?
Did you screw in the upper to the tail light pilar, then wheel wells, triangle block behind the latch place, then the latch plate? can't figure out where to start. I have the light pilars square and screwed in.
 

rydog1130

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You'll want to find center on your rear bed rail support, seat floor pan, and your new pick up bed sheet metal. Once you have center on the pieces you can put your bed pan down in place. Next clamp your striker post in place so that you can position your upper/inner quarters in place. Don't forget there's a filler piece that goes in between the quarter and top of the striker. I had to do a little trimming on those to get them to fit right. I also had to grind the top of my striker post a tad to get my quarter to sit right on them as well. From floor bed to the top of the quarter panel your looking at 19.3" (mine was 19.5") Once you have your inner/upper quarter in place go ahead and get your wheel tubs in, once those are in, place your filler panels in the corner. Lastly id put the striker post braces in place because those really brace things up! Heres where I started building my bed in my thread. Once you have it together don't weld it, put your top on before trying to hang your doors and it will tell you where you need to make any adjustments. Good luck

http://classicbroncos.com/forums/showthread.php?t=249119&page=6
 
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Jamie Chriss

Jamie Chriss

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Got more done. Very slow process with all this new metal!!
 

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bronkenn

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I think I would build that body up using the intended frame for the build fixture. You don't want any surprises after you've done all that work. Ken
 
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Jamie Chriss

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agree, tacking and screwing it together. Will do final fitment once the frame is delivered.
thanks for the advice!
 

rydog1130

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Looks good! I’d hang my lower quarters last after you get your doors on then you can decide where they need to be tacked on the striker post so that they match the curve of your door
 
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Jamie Chriss

Jamie Chriss

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One more solid day in the bag, lots of learning on the fly with a few redos. Slowly coming together everything is straight so far. We have spend most of the last two days trimming and cutting none of the metal out of the box is plug n play. Hoping to have the bed done this week and then moving to the doors. We left the door latch pilar free flowing so I am hopning that gives us some flexability to adjust as we go. I am epoxy painting all the hidden areas as we go, like the rocker panels.
 

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Jamie Chriss

Jamie Chriss

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Feb 28, 2015
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Had my first almost heart breat yesterday! I got some great advice a few pages back about not welding too much and using tons of screws. I was real confident everything was ready to go, welded the wells in along with the filler pieces, somewhere along the way quarter panel dropped a good inch, so when I went to put on the door latch pilar, it was an inch high. I had to dring, chop and saw all the welds I did to get the quater panel to raise... Lesson from another brother I didn't listen to. Anyway I am enjoying the ride!!
 

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