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1970 Rebuild

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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 24

More work on the Bronco,

I had the rear drive shaft shortened and balanced, the front lengthened and balanced as well. Greased and installed. Installed both front seats and seat belts. Bled the clutch. It disengages about half way to the floor. Any ZF gurus speak up if this is too low. I plan to bleed again with my vacuum bleeder to get more pedal.

Did have a plan to get my doors, hood, fenders, top and tailgate blasted as prep for painting but the company ran into a schedule issue and that is on hold until 6 July. I am so close I can taste it.
 

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OP
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 25

More work on the Bronco,

Contacted a company that does dustless blasting (crushed glass and water). Had them do the hood, one door, both fenders, the grille, tailgate and the top. All of this for $450 and they came to my house. Did not do the driver's door since it was rusted under a bad patch job and I already have a new skin. I now need to take all the clean parts to the paint booth on base and paint primer on them and reassemble the truck. After that, I will test the electrical and start to drive this thing again. Final paint will be next spring.

v/r,

SevenT
 

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OP
OP
SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 26

More work on the Bronco,

After putting the transmission in and installing the headers, wound up with collectors pointed at the BC Broncos ZF crossmember. Decided to go 2 into 1 on the exhaust and purchased some Scott Drake headers and BC Broncos 2 into 1 exhaust. New headers installed and waiting on exhaust to arrive. I now have a set of long tubes and dual pipes with Turbo mufflers for sale (local preferred). I now have a shop coming to look at what it would cost to prime and paint the Bronco to finish this thing and let me drive it. Wish me luck.

v/r,

SevenT
 

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OP
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 27

More work on the Bronco,

Installed the grille and fenders and test fit the passenger side door. Pictures show the nutserts I used to mount the rear and tops of the fenders. Door is real sloppy but it is on and the body lines are true. Need to do some adjustments for the bottom and front gaps. That was enough for one day since the nose was on and off at least a half dozen time to make changes and correct mistakes.

v/r,

SevenT
 

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OP
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 28

More work on the Bronco,

Finished up the grille with the lights and found out my Led bulbs will not fit (not enough room for the heat sinks. Ordered some CREE led lights. Installed the fender flares and cut holes and installed the front markers.

Hung the passenger side door and cannot get the gap right no matter what I do. Remember this is a fiberglass tub and the opening does not move because of the body mounts. Look at the pictures and give me some inputs as to what you see that I can do to fix this. Thanks in advance.

v/r,

SevenT
 

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OP
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 29

More work on the Bronco,

My wife bought me a Lincoln Electric MIG welder because I told her it would cost less to weld my own exhasut than to have it welded by someone else. Happy wife, happy life. I finished welding up the exhasut (2 into 1 from BC Broncos). Wired up the blinker and DRL function of the new LED headlights and installed the battery to test the electrical system.

The lights work in the front only, no lights at all in the rear. I will check the rear harness connections. The DRL does not light with key on, another connection to check. The halo only blinks with the passenger side blinker (another connection check).

The worst part is the fact that it will not start since the starter will not engage the flywheel.
An 88 Mustang one is smaller than the one for an 88 F-150 with the ZF. My bad on ordering the wrong parts.

Looks like the entine drivetrain has to come out for flywheel R&R unless someone knows of a way to make this work they way it is in the truck. Any help is appreciated on this to potentially save me some extra work.

v/r,

SevenT
 

DirtDonk

Contributor
Bronco Guru
Joined
Nov 3, 2003
Messages
47,347
Is the flywheel out of the '88 Mustang as well?

Paul
 

DirtDonk

Contributor
Bronco Guru
Joined
Nov 3, 2003
Messages
47,347
And are you grounding all your systems to the frame? Or a common grounding point? Maybe you need to fiddle with that a bit too.

Paul
 

DirtDonk

Contributor
Bronco Guru
Joined
Nov 3, 2003
Messages
47,347
The gap at the bottom front of the door does not look too bad luckily. You can shim out the top hinge from the body to get it to tilt back and down a bit. You may have to adjust the hinges upward then too, but not sure yet. It's a dance.

Paul
 
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 29

DirtDonk,

Is the flywheel out of the '88 Mustang as well?

I ordered the 88 Mustang flywheel thinking it was the same as the 88 F-150 and they are not the same size, the F-150 is larger in diameter, hence the no engagement.

And are you grounding all your systems to the frame? Or a common grounding point? Maybe you need to fiddle with that a bit too.

The front part of the truck is on a single ground on the frame. I may need to bring the rear grounds to the front and make one common point. I grounded all of the instrument panel to a common point and took that to the frame in the front.

The gap at the bottom front of the door does not look too bad luckily. You can shim out the top hinge from the body to get it to tilt back and down a bit. You may have to adjust the hinges upward then too, but not sure yet. It's a dance.


I have to find my door shims that I bought over a year ago and try to do some shimming work. The electrical and flywheel are priorities right now.

v/r,

SevenT
 
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DirtDonk

Contributor
Bronco Guru
Joined
Nov 3, 2003
Messages
47,347
The other odd thing about the Mustang was that during a certain year range they used the same starter motor for an automatic as they did for the manual. Unlike our trucks that use a different one for each style of transmission.
So it's probably a good thing it's also a 157t version or you might be pulling your hair out trying to find out which starter is the right one!

So you're getting a truck flywheel with a 50oz imbalance and the 164t size?

Paul
 
OP
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 29

DirtDonk,

Picked up a truck one at a local parts store. Now I think the clutch I have is too small as well. Both of those I got off of Amazon and can return since the truck never ran. Thanks for the help.

v/r,

SevenT
 

wizard12

Jr. Member
Joined
Jul 7, 2015
Messages
80
Doors

Hey SevenT
To help get the doos aligned better on my bronco designs tub, I ended up taking out the hinges and drilling out thr holes that attach to the body so that I had a lot more ability to adjust the door up/down and in/ out. I found this really helped.

The other thing is I tried shimming under one side of the hinge to fix gap.
My one door would not close enough at the bottom rear, so I put a shim under the outside edge of hinge (not a shim under the entire hinge). This really helped make the bottom close in when it otherwise would be sticking out.
Just some ideas to consider if you already haven’t tried.
Definitely a dance like Paul said.
Good luck.

P.s. Your pictures have really helped with some speed bumps I had on my tub. Keep them coming
 
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 30

Back to work on the Bronco.

Spent the past year travelling a lot for work.

With the impending release of the new Bronco and the fact that mine turned 50 last October, I need to get this finished. I have another event driving the completion of my project. Bronco Super Celebration is coming to Buena Vista, Colorado on Sept 9-12.

I redid the ground in the front of the truck and tied the rear of the truck to the front and now have only four connections. Used 6 gauge battery connectors to tie multiple ground wires into one connection. Fingers crossed.

I had to glue the taillight bucket into the fiberglass to keep it from slipping out of place. Used some Gorilla Glue Adhesive. As for the taillight bezel and the gap created between the bucket and the bezel, I used rubber window seal to prevent water intrusion.

The other picture shows the Stage 8 fasteners on the headers (have been using them for over a decade). Noticed the valve cover gaskets were leaking in the back and go some on the valve covers as well.
 

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OP
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 31

More work on the Bronco,

Finished the shifter boots for the ZF and twin stick. Installed the new SUM-771713B-NK tilt column and Borgeson steering shaft. Need a new steering wheel and horn button (on order from Summit).

Need some help with the connection between the GM comb connector and the Centech connector. Both connectors are pictured. Any experience with this kind of cross species mating is appreciated.

Did not get the clutch bled and lost almost all of the Dot 4 on the last attempt. Will try again.
 

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OP
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 32

More work on the Bronco.

Installed the new steering wheel and horn button from Summit. Did the wiring according to Centech, Summit and others that have submitted solutions. Only time will tell when I system check everything.

Reinstalled the front clip and put the rear end on the rubber. Have the front end up on stands to help bleed the steering system.

The hood fits with no interference from the upper intake. Need to drill holes for hinges and prop rods.

I have to send my thanks to Bronco Design as to the fact that this tub is everything they promised and more. I would have gone the steel route, but would not be as far as I am today if I had done that in both time and money. For those that do the steel tubs, I admire and am jealous of you. I can see the light at the end of the tunnel and can't wait to drive this truck again.
 

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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 33

More work on the Bronco

Got the hood on the truck. Hood is a little high on the passenger side (might be hitting the MAF or air filter. Built some inserts (1/4 inch plywood wrapped in marine vinyl) for the back and installed my 6.5 inch Pioneer speakers. Used the existing holes in the doors to install some 4x10 inch Pioneer speakers. Installed the Dennis Carpenter antenna. Installed the Pioneer head unit. The unit does not play CDs since it is 3.8 inches deep. Best fit for the dash depth to defrost ducts. Installed the center console. Went to try my junkyard acquisition for fold and tumble rear seats and found the seat too wide to fit. Drop back and punt at this point and ordered a fold and tumble from Tom's.
 

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OP
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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 34

More work on the Bronco

Got my TBP fold & tumble rear seat. Got it installed and all I need now are the lap belts. 1970 only had lap belts in the front and nothing in the back. Ordered some 60" ones from SeatBeltsPlus in Oceanside, CA. Started the work to finish the BD tailgate. It is getting closer by the day. I did not get around to working on the limit straps, thanks to the input. Talked to the maker of the tub (Corey Sunday) and he said to use nutserts on the inside of the door opening to attach the limit strap. Still got to look at that one.
 

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SevenT

SevenT

Contributor
Sr. Member
Joined
May 23, 2009
Messages
496
Loc.
Southern Colorado
Phase 35

More work on the Bronco,

Finished the Bronco Design tailgate and have it installed. Scored the license plate spring attachment and installed on the tailgate. License plate will swing just like factory. Installed the limit cables on both sides. Need to do some welding to shorten the cables a bit and do some cutting on the sides of the tailgate to get the cables to move better. Other than that, works fine, looks even better.
Bought some 2002 Heep Wrangler seat covers for the fold and tumble and made the front ones work for the Kia Rio seats. Matching neoprene covers.
Next up is the leaking Saginaw pump which I have a replacement for from Rock Auto. After that electrical checks and this thing is ready for paint and I will be ready for Super Celebration West.
 

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