In progress - From Rust Bucket to Rock Crawler in 5 weeks - updated with pics

This isn't my EB anymore however I still have a special interest in it because I gave it to my brother to make whatever he wanted out of it. This EB started life as a 70 and obviously wasn't taken of too well. From the condition it was in it appears that it has set out in the weather for the better part of 10 or more years. The last owner before me started to make a project out of it and had obtained a few items for it in an attempt to make it trail worthy before he pulled the front cover off the Dana 30 and found the carrier cracked in half and the gears wasted. Apparently he gave up at that point. (It didn't help that the frame behind the rear tires had holes in it) When I looked at it I saw enough stuff to make it worthwhile to pick up for the grand sum of $300 which I recently recouped from the sale of the 3 speed tranny and Dana 20 it had in it. I have made $120 or so off other parts as well and used the door inserts from it and several other misc. parts for mine. Once I picked it apart I offered to give my brother the frame and body if he wanted to make something from it. When we finally got the motor fired up it sounds strong enough that I am loaning it to him so part of it is still mine. (The motor is for sale though since he has another one to replace it some time after SOB is over, price to be determined after it is run at SOB) After I offered it to him it sat in my garage for about a year until about 4 weeks ago when he decided to get it ready for SOB. The plan essentially was to take the drivetrain out from under his 78 Bronco and put it under the 70. (He has 3/4 ton stuff to put back under the 78 as a tow rig) Most of the drivetrain has already been built up this year with the intention of using it under the 70. I.E. 35 spline spooled 9" and alloy axles in the front with an ARB air locker and 5.11 gears. These are driven by a C6 and NP 205. We have most of the EFI system to drop that on top of the motor however it is doubtful it will be on it before SOB. (Too many other things left to do) In the posts below I will walk through what has been done and then will update it with what we have remaining to do. I don't have any pics from the day he pulled it out of my driveway. The above condition pretty much describes it except that by the time he picked it up it was setting on jackstands and we had to stuff axles back in (one broken) and put the frontend back under it just to load it on the trailer.

In the first 3 pics you can see the condition of it 2 weekends ago. At that point he had pulled the body of and then spliced in new sections of tubing to repair the portion of the frame that was rusted through. These pics were Saturday afternoon after we yanked the rearend out of his 78 and put it up under the 70. The rearend was placed in the approx. location it will end up in and then left to be positioned and welded once new shackles have been built and there is weight on it. You might note that he chaose to do a shackle flip and moved the rearend back about 4".

The next pics were taken a few days later. At this point the entire frame had been cleaned up and treated for rust, then followed with paint. The frontend had been put in it (relocated about 1" forward) using the extended radius arms he built last year along with the set of 5 1/2" Cage coils he has been using under the 78 for 10 months or so. He also has the inboard shock hoop welded on and stripped several parts off the frame that would not be used. (Manual steering box, cracked manifolds, etc.) The tranny and transfer case have also been added (for the second time since the first try with the short adapter on the tranny didn't clear at the front driveline). The cross member is a combination of the original one flipped upside down along with a regular C6 tranny mount.

The first pic below was taken a day or two later after we dropped the body back off the ceiling onto the frame. Take note of what we used to get the frontend positioned under it at that point. Following this we ripped the rear wheel wells out and started reworking them to fit the seat from a full size Bronco and to fit the 38.5 tires up in them. (Mainly this was started to use up some time before tackling bigger projects so it was dropped at that point to be picked back up once it is otherwise trail worthy) The next big project was to get a power steering box installed. He chose a saginaw box for the extra strength since he has broken 3 of the stock big bronco boxes (snapped the sector shaft off all 3 of them). This took a full day to get installed along with a 78 F250 steering column (with the tranny shifter). While he was building that I put a raised track bar mount on and installed the track bar to keep the frontend centered. After the steering was installed he pulled the entire front clip off and cut the inner fenders and core support from them. Both were beyond repair so he decided to tube the front clip using 1" x .120 dom tubing. I piddled around doing misc. small stuff like getting the rear tail light housings installed, parking lights in, and the busted headlight out along with putting the windshield back on and one of the 90 Probe bucket seats donated from mine after I retired them for racing bucket seats. The second pic below was taken last weekend after the above had been completed and at that point it looks like it is shaping up some.

I didn't get any more pics this last evening however at that point the dual battery boxes were built for it which hang from the tubing, the transmission linkage has been modified and installed, the hydroboost brake booster was installed except for the lines. The accelerator has been modified to use a cable so it clears the hydroboost, part of the wiring has been done, a hood prop rod has been added, and half of the exhaust has been added.

Items still remaining include:
Obtaining and installing a radiator
Installing the power steering pump
Installing an alternator (Probably a 3G)
The remaining seats need to be installed
Roll bar needs to be bolted down and a windshield brace added
Steering wheel needs to be changed
Front bumper needs to be built and the winch installed
Lines need to be built for the hydroboost
Tranny cooler lines need to be added
Remainder of exhaust needs to be built
Wheel well mods need to be completed
Steering column needs to be wired in
Ignition switch needs to be wired
CB and antenna need to be installed
Rear Shackles need to be built
Spring perches need to be welded
Drivelines need to be shortened
Seat belts need to be installed
Gas tank needs to be installed
Guages need to be installed

Hmm... I'm sure I forgot a few things.

Here is where it gets good. Sunday it will be 4 weeks into this project. Next weekend this needs to be complete if we are going to give it a test run which gives us just over a week to make it trail worthy. We have accomplished a lot but there is still quite a bit remaining. The plan is to have it ready for SOB in 2 weeks but as mentioned it needs a test run first. Wish us luck because we are going to need it.

Just posting a quick update. I'll probably get some more pictures today.

Items still remaining include:
Obtaining and installing a radiator Done
Installing the power steering pump Done (still needs a belt)
Installing an alternator (Probably a 3G) Done
The remaining seats need to be installed
Roll bar needs to be bolted down and a windshield brace added (Still needs the brace)
Steering wheel needs to be changed
Front bumper needs to be built and the winch installed
Lines need to be built for the hydroboost Done
Tranny cooler lines need to be added Done
Remainder of exhaust needs to be built Done
Wheel well mods need to be completed
Steering column needs to be wired in
Ignition switch needs to be wired Done
CB and antenna need to be installed
Rear Shackles need to be built Done
Spring perches need to be welded Done
Drivelines need to be shortened Done
Seat belts need to be installed
Gas tank needs to be installed Done
Guages need to be installed Done
Weld lower rear shock mounts in

In addition we decided to put the EFI in which just needs the wiring finished

Coming along nicely! Thanks for the update. More pics please!

Someone's working their hiney off!

How did you install the full width cast wedge Dana 44? Did you move the wedges, coil mounts, and radius arm mounts or just leave verything in place and wedge them in? Can you show some close up pics? This is on my near future to-do list. Thanks.

Today's update. I didn't get any pictures yet but I plan to get some tomorrow when we drive it out. We had hoped to do so today but it was too late before we had it running right. Today we spent almost the entire day finishing up the EFI. I.E. We had to run the fuel lines, install the fuel pump, and add a couple of sensors. Then I had to lengthen a some of the connectors to fit right. After this was all apparently done we had to work out the gremlins. This entailed tracking down the cause of the check engine light not working, (That is what we get for not looking at the diagrams first because it was wired to a ground instead of the ignition) and then the fuel pump relay. (Again grounded where there should have been power) The second one was easy though after the check engine light was figured out. Once this was figured out it fired right up and 5 minutes later was purring nicely. We also took care of getting all of the fluids up to the necessary levels (tranny, power steering, coolant, etc.) and checked the vitals. In theory it should now roll out under it's own power tomorrow. Everything remaining now is just a matter of busting it out.

Items still remaining include:
Obtaining and installing a radiator Done
Installing the power steering pump Done
Installing an alternator (Probably a 3G) Done
The remaining seats need to be installed
Roll bar needs to be bolted down and a windshield brace added (Still needs the brace)
Steering wheel needs to be changed
Front bumper needs to be built and the winch installed
Lines need to be built for the hydroboost Done
Tranny cooler lines need to be added Done
Remainder of exhaust needs to be built Done
Wheel well mods need to be completed
Steering column needs to be wired in
Ignition switch needs to be wired Done
CB and antenna need to be installed
Rear Shackles need to be built Done
Spring perches need to be welded Done
Drivelines need to be shortened Done
Seat belts need to be installed
Gas tank needs to be installed Done
Guages need to be installed Done
Weld lower rear shock mounts in
Replace throttle cable for EFI

In addition we decided to put the EFI in which just needs the wiring finished Done

mp said:

How did you install the full width cast wedge Dana 44? Did you move the wedges, coil mounts, and radius arm mounts or just leave verything in place and wedge them in? Can you show some close up pics? This is on my near future to-do list. Thanks.

Click to expand...

We just left it and put them in as is. He said he might go back and drill the lower plates closer to the center though. For now he is going to try it as is though. If for no other reason than that we have run out of time. Tomorrow we focus on the necessities (Seating, seat belts, roll bar) and then he can piddle with it in the evenings Monday and Tuesday. We may do some small things Thursday after he gets down there as well. (I'm heading out Wednesday so tomorrow will be probably be my last day helping him on it)

lookin good ;D thats alot of work in a short amount of time

One more update. We accomplished a lot today. With it out in the open we were able to get around it easier so we were able to knock out a lot of the little stuff. I've added a few things that we turned up today and in many cases finished. The items remaining will be pretty easy to finish up or are not important for this trip (I.E. Wiring in the column isn't necessary since it has tailights and headlights) with the exception of the front bumper and winch. Not certain if they will get done yet or not. A few of the smaller items can even be done Thursday after he gets there.

Previously Completed items from above:
Obtaining and installing a radiator Done
Installing the power steering pump Done
Installing an alternator (Probably a 3G) Done
Lines need to be built for the hydroboost Done
Tranny cooler lines need to be added Done
Remainder of exhaust needs to be built Done
Ignition switch needs to be wired Done
Rear Shackles need to be built Done
Spring perches need to be welded Done
Drivelines need to be shortened Done
Gas tank needs to be installed Done
Guages need to be installed Done
In addition we decided to put the EFI in which just needs the wiring finished Done

Items completed today:
Install Bracket for Flag Done
Install Fire Extinguisher Done
The remaining seats need to be installed Done
Roll bar needs to be bolted down and a windshield brace added Done
Wheel well mods need to be completed Done
CB and antenna need to be installed Done
Weld lower rear shock mounts in Done
Replace throttle cable for EFI Done
Trim and bob wheel well openings Done
Seat belts need to be installed Still Need to install front belts

Items still remaining include:
Diagnose Charging system (Doesn't seem to be charging)
Install Front Shocks
Install CO2 tank
Install ARB air lines
Install hood pins
Install air cleaner
Overflow bottle
Front bumper needs to be built and the winch installed
Tie up hanging wires
Steering wheel needs to be changed
Steering column needs to be wired in

If I get enough of my own stuff done tomorrow then I may go over and help knock out more tomorrow evening.

Here are some pics from today.

BTW, This Bronco has been dubbed "Second Chance" because it was purchased as a parts rig that came very close to going to the crusher.

Looks good!

Way to keep it alive. Your almost there, keep up the hardwork

Well, I made it over there this evening to help out some to wrap up a few more things. Here is the list as of this evening.

Previously Completed items from above:
Obtaining and installing a radiator Done
Installing the power steering pump Done
Installing an alternator (Probably a 3G) Done
Lines need to be built for the hydroboost Done
Tranny cooler lines need to be added Done
Remainder of exhaust needs to be built Done
Ignition switch needs to be wired Done
Rear Shackles need to be built Done
Spring perches need to be welded Done
Drivelines need to be shortened Done
Gas tank needs to be installed Done
Guages need to be installed Done
In addition we decided to put the EFI in which just needs the wiring finished Done
Install Bracket for Flag Done
Install Fire Extinguisher Done
The remaining seats need to be installed Done
Roll bar needs to be bolted down and a windshield brace added Done
Wheel well mods need to be completed Done
CB and antenna need to be installed Done
Weld lower rear shock mounts in Done
Replace throttle cable for EFI Done
Trim and bob wheel well openings Done
Seat belts need to be installed Done

Items completed today:
Diagnose Charging system (Doesn't seem to be charging) Done
Install Front Shocks Done
Install CO2 tank Done
Install ARB air lines Done
Install hood pins Done
Install air cleaner Done
Overflow bottle Done

Items still remaining include:
Front bumper needs to be built and the winch installed
(This may get done tomorrow but if not then it will not be done for this trip)

These items will be put off until after he arrives unless he manages to get any of them done after the front bumper and winch:
Tie up hanging wires
Steering wheel needs to be changed
Reinstall diamond plate rockers
Steering column needs to be wired in

It will be interesting to see how this does this weekend. We are 1 day over 5 weeks now and we think it is trail worthy at this point. I.E. None of the items on the list above as remaining are show stoppers that would keep him from running it. At this point it all comes down to how well we did putting it together in such a short time frame. The exception here is the motor which may be a full 35 years old even though it sounds healthy. The EFI on it now makes it purr very nicely and the lifter that was initially making noise after having sat for several years has stopped making any noise. It isn't the prettiest at this point but the drivetrain under it should be plenty stout for anything we will throw at it this weekend.