Inner fender, kick panel, door post post

[Lunar-tic]

After a few set backs ("business trip" to East Africa) I am back to work on my cancer patient. I have most of the front complete, just need to strip the grill down and see what lies underneath. I have all of the DIY bedliner out and the new family cage in. Still need to weld up all the unused holes in the floor and repair a few small spots. One place on the drivers quarter panel might be a little more involved than the others. Any tips for me in regards to fabricating that patch? And yes, that hole will be enlarged to remove all the rust.

Thanks

Bill

 

[D.R.Y.]

Great job, I am just about finished restoring my chassis and have been procrastinating the body work. Mine needs almost all the metal replaced from the B pillars forward. This gives me some confidence to give it a go...

 

[Lunar-tic]

It's a lot of work, but nothing that couldn't be done at home. Yesterday I found some of the worst repair work so far on the lower quarter panel. Should have taken a picture. They hammered the rusted metal in and spot welded a patch over it. All hidden under copious amounts of bondo. I have to give it to the guy, his ability to hide stuff with bondo is impressive.

 

[NGABronco]

They hammered the rusted metal in and spot welded a patch over it. All hidden under copious amounts of bondo. I have to give it to the guy, his ability to hide stuff with bondo is impressive.

HaHa!!! Great work William, I bought one that I thought the dr. door post was solid, when I tried to take the fender off I found that it had been welded to the door post!!! LOL That's why it was so solid!!!%)%)%)

 

[Lunar-tic]

Lots of work accomplished this weekend. You all got me motivated. Last pic is some of the nonsense I had to cut out. The Bondo Bandit strikes again!

 

[Mikel C]

Which company did you purchase you fender aprons and fenders from?

 

[Lunar-tic]

All of my metal came from the Bronco Graveyard. I got the pre-cut fenders since my quarter panels were already cut and I like that look. The all of the metal was decent, but I did have to massage most of it to get it to fit/line up. I assume that's expected when putting new metal on a ~50 year old vehicle.

 

[nutter3]

William, --Thank you so much for documenting all this. I'm about to tackle the kick panel, inner and outer rockers, door post, and front floor pans on mine. With all you pictures I can really see how this stuff is held together. I'm a little worried about getting it apart.
Great work.

 

[Lunar-tic]

It is a little intimidating at first, just take your time, measure everything before your cut out the old stuff, and brace the dash. I put a bottle jack and a couple 1x4s between the dash and the trans tunnel to keep it from sagging once I removed the door post. Use weld through primer and don't be timid with the cut off wheel. There's no such thing as cutting out too much of a rusty panel.

 

[Lunar-tic]

Got a little side tracked with a new air cleaner, but I did have time to fabricate a bracket for my rear Corbeau bench. I also welded up all leftover holes in the bed. Inching closer to getting it to the paint and body shop.

 

[EB_1970]

Great job! i am needing to do the same work. the PO of my bronco hide a lot of rust with bondo as well. Thanks for posting all of the pics!!

 

[Lunar-tic]

Thanks, I am really close to it being ready for the paint and body shop. A few more spot welds, another quart of POR, and a tube of caulk and I should be about done.

 

[Piglet]

man, thanks for all the pics. deff helped ease the anxiety of tackling some rust finally. on a side note, i realized i bought your old bolt in roll bar from you. hope things are going well and cant wait to see to finished product!

 

[Howard2x4x4]

Nice job, William! Dandy welding and fabrication!

 

[Real Big Stache]

Are you spot welding the body panels back on or stich welding?

 

[mdside]

Lots of work accomplished this weekend. You all got me motivated. Last pic is some of the nonsense I had to cut out. The Bondo Bandit strikes again!

I am wondering what you are planning for the welds in the fourth photo from this post? I see that you attached the lower half of the two panels together, will you be going the whole way up and getting rid of that panel joint all together?

I am very interested and sub'd to this thread, I have most of the same work to do... if not more and am very much a visual learner!

Keep up the good work and keep those posts & pic's coming!

 

[Howard2x4x4]

All of my metal came from the Bronco Graveyard. I got the pre-cut fenders since my quarter panels were already cut and I like that look. The all of the metal was decent, but I did have to massage most of it to get it to fit/line up. I assume that's expected when putting new metal on a ~50 year old vehicle.

Nice work, William! I just called Jeff's Bronco Graveyard to ask about the pre-cut fenders and the kid on the phone didn't know anything about them. Do you have part number? Price? Thanks, and keep up the good work! Howard in Beautiful West Michigan

 

[Lunar-tic]

man, thanks for all the pics. deff helped ease the anxiety of tackling some rust finally. on a side note, i realized i bought your old bolt in roll bar from you. hope things are going well and cant wait to see to finished product!

Things are progressing, we moved recently so I haven't been working on the Bronco nearly as much as I would like. Hell, as you can see, I haven't been on this site in a while. Having that said, I'll put in some good days last weekend and I'll post the pics shortly. Really close to getting it in to paint and body.

Hope you are happy with the roll bar, it is a beast.

 

[Lunar-tic]

Are you spot welding the body panels back on or stich welding?

Sorry for the late reply, I spot welded everything back in, POR15 the seams, then put seam sealer on them. I'll probably go back over it with another coat of POR15 or some type of coating.

 

[Lunar-tic]

I am wondering what you are planning for the welds in the fourth photo from this post? I see that you attached the lower half of the two panels together, will you be going the whole way up and getting rid of that panel joint all together?

I am very interested and sub'd to this thread, I have most of the same work to do... if not more and am very much a visual learner!

Keep up the good work and keep those posts & pic's coming!

I spaced out the spot welds in the seam, then went back and used a cutoff wheel and a dremel to grind them down. I'll slather some POR15 in there and follow it up with seam sealer. Shouldn't be able to see the welds after that...I hope.