Broncoski ( My Build Thread)

Nowik35 · Sep 24, 2018

Ok I will finally start my build thread and keep up with my progress on here. I love going through others stories and see the progress. Mine is currently a rolling frame already but I started from scratch, LOTS OF RUST. so much originally that I contemplated even starting this project or was it to big for me. But I decided to dive in , not having any experience but I figured the internet can help me. That being said I will attach some pictures of the day it came home and add threads of each milestone as I remember them. Also being a proud Polak I decided to name my project Broncoski. As it came home it was the original

170 inline 6
3 on the Tree transmission i believe RAN
Dana 20 with the T stick
Rear 9 small bearing with 10" drums ( I feel like its the most expensive and rarest of combinations for every time I was looking for parts)
Dana 30 in the front with King pin axles
who ever had it before me put a 3.5 inch lift on it.

So it came home on Cinco de Mayo 2018 and I had it started torn apart the next day. The person told me it hasn't turned over in more than a decade so I had a project on my hand.

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Nowik35 · Sep 24, 2018

So the first step was obviously to tear it apart. My goal was to strip it down to the last bolt. So I started doing just that. Now if I could do it again. I should of tried to at least start it first but at that time I didn't think of doing that. I knew I would have to tear it apart. Also As I was tearing it apart I learned a cut off off wheel is a mans best friend. Most bolts had to be cut , because I could wrestle with them and they would eventually shear off any way do to the heavy rust. All these pictures are over a period of several weeks.

tasker · Sep 24, 2018

love the stance of it!! it is sooo worth it in the end! good luck and let me know if might need something

markw · Sep 24, 2018

Well, you have a project! Stay the course and you will be so proud of your new EB!

bronkenn · Sep 24, 2018

Nice project. Don't let it overwhelm you. If you get discouraged with something, walk away and do something a little less taxing. A lot of people on here have rebuilt ones that were like that and they came out nice. Ken

1strodeo · Sep 24, 2018

Nowik35 said:
Ok I will finally start my build thread and keep up with my progress on here. I love going through others stories and see the progress. Mine is currently a rolling frame already but I started from scratch, LOTS OF RUST. so much originally that I contemplated even starting this project or was it to big for me. But I decided to dive in , not having any experience but I figured the internet can help me. That being said I will attach some pictures of the day it came home and add threads of each milestone as I remember them. Also being a proud Polak I decided to name my project Broncoski. As it came home it was the original

170 inline 6
3 on the Tree transmission i believe RAN
Dana 20 with the T stick
Rear 9 small bearing with 10" drums ( I feel like its the most expensive and rarest of combinations for every time I was looking for parts)
Dana 30 in the front with King pin axles
who ever had it before me put a 3.5 inch lift on it.

So it came home on Cinco de Mayo 2018 and I had it started torn apart the next day. The person told me it hasn't turned over in more than a decade so I had a project on my hand.

It's people like you, and me, and bronkenn, and lots and lots of other members on here that are the reason so many Broncos survive that would have otherwise returned to dust...BRAVO and welcome to the addiction!!! ;D

sprdv1 · Sep 24, 2018

Glad to see you doing it yourself.. Good luck and just take one thing at a time

PickleJar · Sep 24, 2018

It’s a beaut CLARK! A real beaut!

I mean that, it’s awsome, thanks for saving it!

fordfan · Sep 24, 2018

We have subscribed! Watching it anxiously !!!

Nowik35 · Sep 24, 2018

Ok my next big milestone was definitely the day I finally seperated the frame from the body. Did it my self with an engine lift. Thanks to Matts garage for idea on YouTube. So also as you may notice all the wood. I'm a real cheapo so I used any means necessary to save money. Also promised the wife I'll find every way possible not to spend money that means use scrap wood to brace the body and built a body cart out of a few pellets. Price FREE

Nowik35 · Sep 24, 2018

On to the rest of frame. Next was the engine lift and drive train separation. Also a fun millstone.

Bonefizz · Sep 24, 2018

You are movin! Keep it up!

Nowik35 · Sep 24, 2018

This is the very discouraging day. Evaluating the rot. The damage. How much work I actually need to do. This was the day i wanted to give up bc I thought the damage was way above me. But I gave it a few days of thinking about it and decided to give it a go. I know I could of just bought a new frame from cjpony but I want to actually have a restored classic not a replica. Here is all the rot that day I really noticed.

Nowik35 · Sep 24, 2018

Ugh this was the dirtiest of this tasks. Of course me being stubborn and cheap. i refused to pay for a sand blasting or I didn't want to buy my own. So i sanded the WHOLE frame by hand with an angle grinder. I used wire wheels. Wrie knot cups. Sand paper wheels. Think cut off grind wheels. I used them all for this job. O and lots of face masks. There was a rust cloud in my driveway for three days straight. But here it was.

Nowik35 · Sep 24, 2018

Last part of the disassembly was separating the axles from the frame and have a truly separated frame.

Nowik35 · Sep 24, 2018

So I saw people with rotisserie frames but I also noticed my engine lift is just as handy. Anyways once ihad it hung up it was time for the final touches of sanding to get it ready for welding. This really showed all the damage.

Nowik35 · Sep 24, 2018

WELDING WELDING WELDING! so before this project I never even held a welder in my hand. So first i had to get a welder then I had to teach my self how to use it. And finally I started with the frame. My approach was one patch at a time. I would cut out a cancer and weld in a patch 100%. I did that because I wanted to make sure I didn't risk twisting or bending the frame. I don't know that logic seemed to make sense to me. One thing I shouldof done was ground down the welds after each patch but like an idiot. I saved all the grinding until the end. I'll post that in the next post. This one was all about just welding. Well the very first patch I welded and did ground down but then I didn't grind until I finished welding everything. Here are my welds. Please no judging!

Nowik35 · Sep 25, 2018

Finally after finished welding up my frame which took me a good 2 months. There was a lot of rust removal. The last step for the frame was grinding all those welds smooth and oh boy was this step hard and long. One piece of advice to future warriors. Do not grind in your driveway. I didn't think anything of it when I was done grindingbut the next day after it rained OH BOY! I got an ear full from the wife. The whole driveway turned ORANGE. all the grind shavings rusted on my driveway and kind of fused with the driveway. So I had too power wash the driveway like 4 times. Still not100% cleaned

. Anyways here are some pictures of the frame finished and ground. Ready for paint.

chuckyb · Sep 25, 2018

Wow! You are working hard up there. My NJ truck had similar amounts of body rust and dirt. Good to see it getting saved. What’s your vision for it ?

Rustytruck · Sep 25, 2018

Looks like you have the weld thing covered. Protect the frame number stampings. They have to be readable when you go to title the truck.

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