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1971 Bronco Build - Catch Up

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
I started the build on Thanksgiving week, 2006. The Bronco was sitting for 5 years after the previous owner had a fire. The fire started from a fuel leak and spread through the electrical system. The fire was hot enough to melt the knobs on the dash and crack the windshield.

I'll post the pictures in sequence. These pictures include the hood after the fire, cleaning and undercoat removal, and my lovely bride of 35 years. By this time I had already replaced the floors, filled holes and made other sheet metal repairs.
 

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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build -

These pictures include frame with factory welds cleaned up, POR 15 and Black Cote applied, tub painted with POR-15.
 

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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build - continued - Topcoat

These pictures include the top coat with dark red POR-15 Hard Nose paint. It is hard to get a really fine finish with the Hard Nose paint. If I were to do it again, I would not use the Hard Nose paint for a top coat because it chips rather easily when compared to clear coat. I'd stick with base coat/clear coat because it is tougher and easier to repair.
 

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mp

Bronco Guru
Joined
Dec 22, 2001
Messages
2,914
Loc.
Austin, TX
Looks great. I thought about using the POR hardnose paint.....maybe i will reconsider..
 
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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build - Continued -

These pictures include the NP-435, my bride helping with the transfer case rebuild and installation of Terra Low gears, twin sticks set up to ensure transfer case would shift after rebuild, installation of transmission and transfer case. I am using poly bushings to replace all the rubber bushings.
 

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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build -

These pictures include engine build, painting, and installation, again with my bride helping. Engine is a 289 with mild performance modifications. You'll see later that there is a change.
 

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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build - Major Change

In early May, I started prostate cancer treatment. Caught it early and now it is gone - get that PSA checked boys! Since work in the shop was cut back, I started reading about diesel conversions for all kinds of vehicles including Broncos.

The pictures show delivery of a Cummins 4BT I got out of a bread truck from a guy in Kansas. It was remanufactured by Cummins in 1995 an has 80,000 miles on it. It ran sweet in the truck and is barely broken in. Also a picture of the cleaned and painted engine.
 

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Dan76

Sr. Member
Joined
May 17, 2006
Messages
895
Thats sweet! What made you decide to do the cummins after you got the 289 all done and in :p
 
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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build - Frame and Firewall Mods

These pictures show frame and firewall modifications. I cut off the factory V8 motor mounts and modified them. I welded the modified mounts to the frame. My goal for the motor position was to maintain the same location for the bell housing, transmission, and transfer case. The 4BT is much taller than the V8 and I wanted to keep as much clearance as possible to the front axle. I will have to modify the hood, but it is better to have the clearance on the bottom and make some changes to the hood. Because of the passenger side motor mount location, the corner brace on the frame had to be changed. I also added a 3/16 inch thick plate to the firewall for strength and to help mount the hydraulic clutch master cylinder. The plate is drilled to accept a hydroboost later.
 

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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
Why the change to Cummins?

Thats sweet! What made you decide to do the cummins after you got the 289 all done and in

I own a couple of other diesels and grew up around them. There is a market for the 289 engines and a guy I know in Louisiana is interested so all I'll lose is some labor. Also, the diesel makes good torque at low RPM. So, even with tall tires, I can keep the 3.50 gears and hit my target RPM of 1800 on the highway. Last, there's not many around.

Thanks for the question,

James
 
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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build - Engine Mounted

The first pictures show the 289 before the change and weight of the drive train an chassis. The next pictures show the 4BT installs and the new weight of the drive train and chassis. The changes added about 270 pounds. I have a James Duff 3.5 inch lift installed and the difference in height was about one half inch. Also shown is the oil pan modification to ensure the differential does not hit the oil pan.
 

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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build - Body Back On

These pictures show the tunnel modification for the NP-435, the body on the lift ready to lower, the engine and NP-435 fit. I used poly body mounts and added a one inch body lift. I modified the down pipe from the turbo and wrapped the down pipe with header wrap. There is about on half inch clearance between the down pipe and the fire wall. Also shown is the exhaust. The muffler is a Moroso race muffler that I've used on other vehicles. The single exhaust exits just forward of the rear tire on the passenger side.
 

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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build - Dash, Wiring, Dana 20 Output

The pictures show modification to the dash to move the glove box and fill some holes. I painted the dash black with a base coat/clear coat. I also added a 3G alternator and water outlet from a 1996 Cummins diesel Dodge to make the coolant routing easier. I rewired using a generic wire harness. Lesson learned - use a Bronco specific harness. I spent many hours tracking down connectors for switches because the originals were all destroyed by the fire. Also after reading about Dana 20 output failures on this site, I installed a beefed up version.
 

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broncomania

Sr. Member
Joined
May 5, 2007
Messages
778
Loc.
nc
this is a nice build. looks like pristine work.
the diesel swap is way cool. will be checkin back in for updated pics.
 

bax

Contributor
Old Member
Joined
Aug 22, 2005
Messages
14,491
Very nice, keep us informed about the diesel install details. Oh heck tell us about everything.
Your build looks very good.
 
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jghflys

jghflys

Jr. Member
Joined
Mar 15, 2007
Messages
117
Loc.
Texas
1971 Build - Cage Construction

When my son came up for a visit during Thanksgiving week we started on the cage. He lives in Louisiana and comes to Arkansas to visit for a week every year at Thanksgiving. He has a J**P build going and we went together and bought a Pro Tools bender and dies for cages, supports, bumpers ... We modified the bender to use a hydraulic ram and air driven pump and put it on a roll around stand (the stand was formerly part of the Cummins motor stand.)
The cage is 1.75X.120 DOM tubing. I designed it using Bend Tech Pro. I am amazed at how accurate the tubing bends and cuts are if you do your part and measure carefully. We got the bulk of the cage bent, cut, and tacked in place, and there is still a lot of work left to add the remaining supports, build frame ties, finish welding. more to come on the cage.
 

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