77 Bronco Sport frame up resto

Crawdad · Sep 20, 2018

Broncanuk said:
Stock 77 plastic fuel tank.

I gotcha, I thought you were building a whole new tank.

Broncanuk · Sep 20, 2018

Here goes front clip, door posts and floors.

Broncanuk · Sep 20, 2018

And this is already year 2015, time went by fast.

Broncanuk · Sep 20, 2018

After stripping paint and lots of cheese from rear part of the tub, I decided not to waste any time trying ti fix the holes, but built it basically from scratch. Funny enough - rear floor for the most part of it was like new, but some small areas were fully rusted out, so were wheel wells, inner quarters - total wreck, outer quarters - salvageable but would take a long time to fix.

Broncanuk · Sep 20, 2018

Sometimes , or I should say - most of the times it was real PITA to make those aftermarket sheet metal parts fit. So this is already beginning of 2016.

Broncanuk · Sep 20, 2018

And this is summer of 2016

Broncanuk · Sep 20, 2018

One day a little guy came to help his grandpa. Of course I had to promise him that he will drive it once he gets his license, and behaves until then;D

jaybird29 · Sep 21, 2018

Nice job. Excellent fab skills!

svastano · Sep 21, 2018

Looking Good!

Broncanuk · Sep 21, 2018

Thank you!

Broncanuk · Sep 21, 2018

At this point I removed body from the chassis and put it on rotisserie. As I mentioned before I opted for all new sheet metal, I decided that it will be easier to cut out and weld in fuel door mounts then try to repair old fender. Again, nothing was coming together without struggle. At some point when I thought all looks good, all final welds were done, and then I rotated the body and o, crap...

. Rear bottom ends of outer fenders didn't meet with corner pieces properly. Couldn't see it from the upright position, and probably nobody would notice, but now I know that there is a flaw. So I bit the bullet, cut out perfectly good welds, cut some strips out of those corner posts, made them fit more or less nicely.

Broncanuk · Sep 21, 2018

Here what was happening:

Broncanuk · Sep 21, 2018

And this is 2017 already.
And I was getting tired of that sheet metal , so I switched to the engine. It was kinda rebuilt before, but whoever rebuilt it used old gaskets (?????) and lots of RTV. So I decided to re-gasket it, clean up heads and re lap valves, new crankshaft seals too.

Broncanuk · Sep 21, 2018

Then there was an attempt to do something that I absolutely hate to do, and therefore don't have enough patience to do it right - paint job. I painted rims.
After that I decided to contract a friend of mine, retired professional body man from Ford factory to finish the tub when it comes to that point. After rims were done, rolling chassis finished, and engine installed.

Broncanuk · Sep 21, 2018

Fabricated my own exhaust out of universal muffler and exhaust pipe pieces from auto parts store, again with a bit of the help from little guy;D

Broncanuk · Sep 21, 2018

By the way, the airplane on background is my other hobby - RC flying, which interferes aLOT with Bronco project in the summer time;D

Broncanuk · Sep 21, 2018

Back to ever-loving pain in the butt sheet metal work. Cleaned old rubberized undercoating and got it ready for primer.

Broncanuk · Sep 21, 2018

Had my buddy George prime and paint engine bay, undercoat, and put tub back on the chassis for final body work.

Broncanuk · Sep 21, 2018

Front clip and engine bay painted

Broncanuk · Sep 21, 2018

I put a Herculiner on the interior floor.

77 Bronco Sport frame up resto

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