7 Year Itch (Condensed)

[klcornett]

My first order of business is a big thank you to all forum members. I have learned a tremendous amount and had the good fortune of reaping the benefits of lessons learned without the pain and expense of having to learn them myself. Thanks everyone!

This is the second Bronco I've owned. The first was a 1970 that I purchased in El Paso, TX in the mid 80s, implanted a 351 Cleveland and NP435, discovered Four Wheeler Magazine's treasure hunt, and drove it across country twice. I kept it until 1996 when I sold it before going overseas for three years. As many have bemoaned, I regret it to this day.

I purchased my current Bronco in October 2017. The tub was in rough condition with rust thru throughout, and other than the cowl area, needed replacement. My plan was to repair the metal, add disk brakes and complete a simple stock refurb. Not the way it turned out.

October 17 Pics of Bronco, body panels stripped, and body off the frame.

 

[klcornett]

November 2017
Blasted the frame, painted it with rust encapsulator followed by chassis black. Added front disc brakes and a 2.5 inch lift (scope creep) and purchased the Bronco in a box option to replace the tub components.

 

[klcornett]

December 2017
Over the Christmas holidays and vacation accomplished most of the initial sheet metal work on the tub. The entire tub was assembled with sheet metal screws using measurements found on the forum and those taken from the original tub when possible. I was able to follow several build threads during the process. a tremendous help.

 

[klcornett]

January 2018
Continued with sheet metal installation and begin fit up of body panels.

 

[klcornett]

The next five years, major scope creep! Countless iterations of installing and aligning body panels. Realizing I'm not a body person and decided to purchase new doors, fenders, hood, tailgate and windshield frame. Thinking it would be nice to have fuel injection and automatic transmission. Purchase a 2000 Explorer AWD drive as a donor. May as well throw in power steering. Couldn't find anyone interested in painting it for me, so finally made the plunge and on a rotisserie.

 

[klcornett]

December 2023
Realized that I wanted to work on my Bronco more than I wanted to work. Pulled the cord, quit working and began life as a somewhat full time Bronco restorer.

Placed the top on for fitment and then on to grinding welds and stripping for primer and paint.

 

[klcornett]

February
First coat of epoxy primer and seam sealer.

 

[klcornett]

March
After sanding, second coat of epoxy and 2 coats of Boxwood Green color matched Raptor LIner

 

[klcornett]

April
Stripped remaining body panels and extended my work area.

 

[klcornett]

May
High build primer and block sanding. Separated Explorer donor body from frame and drivetrain.

 

[klcornett]

June
After many hours of blocking, re applying primer, blocking and final epoxy primer, got the base and clearcoat on the tub.

 

[klcornett]

July
Painted the body panels. I wasn't able to get a match for Argent Silver so went with 2011 GMC Quicksilver metallic for the grill and rims. I spent most of my time removing and cleaning explorer parts to transition to the Bronco. Removed the wiring harness and sent to Garry Vance (EFI Guy for rework).

 

[1969]

Great work!!

 

[hyghlndr]

Wow, great looking work!

 

[Tricky Dick]

Realized that I wanted to work on my Bronco more than I wanted to work. Pulled the cord, quit working and began life as a somewhat full time Bronco restorer.

Teach me your ways! I've realized this for a very long time.

 

[klcornett]

August
Rebuilt the transmission to install the new output shaft required for the AA adapter and D20. Changed the rear end gearing from 3.50 to 4.11. Installed the Explorer engine and transmission into the Bronco frame, and finally the tub back on the frame.

 

[klcornett]

September
Making everything work together, maybe, hopefully?
I retained all of the Explorer emissions. I was able to keep the Explorer air box, purge and vent valves as well as the charcoal cannisters. I built a bracket and mounted the cannisters and vent valve underneath the driver's side tub between the frame and rocker. I mounted the purge valve between the driver's side inner fender and cowl. I modified the Explorer fuel tank pressure transducer to connect to a hose barb style and added a rollover valve to connect the tank to the vent valve.
Cut the Explorer cold air box and removed 1 inch, riveted and glued it back together and rotated it 90 degrees so I could use the original box.
Converted the fuel lines to braided hose and added AN6 fittings along with original EFI fittings in order to use the stock Explorer fuel filter.
Cut the metric connection off the power steering line and brazed it onto an SAE line to retain the Explorer pump.
Lowered the power steering pump and coil pack
Rotated the EGR elbow and used the Explorer accelerator cable and mount
Fabricated a spacer to move the fan shroud further onto the fan
Probably a lot of other things I'm not thinking of at the moment.
Started it for the first time. Side note it fired on the first crank. You may hear some lifter clattering on the video but it went away after a minute or so after they got pumped up from sitting so long.

 

[klcornett]

October
Got the wheels on and the top painted, continual tweaking, installing, filling, tightening of every component. Wired the Dakota Digital dash gauge. The best thing is that it moves in and out of the garage under its own power now.

 

[klcornett]

November
Began installing body panels and trim. All has gone well so far. Installed seats and roll bar. Cut and buffed the paint.

Teach me your ways! I've realized this for a very long time.

They just sort of swelled up and boom!

 

[klcornett]

Great work!!

thank you