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I was able to cut the passenger side floor out today. Most of this floor is in great shape but there was some sort of patch riveted where the floor angles up to meet the firewall and it looked like it was a future rust problem in the making so I cut it out. I marked a 1" wide line all around...

I used one from an old school bus on my son's Bronco. It gives you a little more leverage and adjustability than the Mustang handle. It works on the Caddy rears, which take some force to make hold. We mounted it on the right side in front of the t-case shifter so you weren't trapped inside...

I spent a lot of time with my body hammers, self tapping screws and a propane torch flattening out the flanges and making sure the panels are compressed together as much as possible. I drilled holes for spot welds in the post for the front flange and in the kick panel for the back flange...

I moved to the front flange after I fixed the kick panel. This one came off a little better and I was able to remove it without much trouble. The rocker was full of dirt and wasp nests. I cleaned it the best I could with a scraper and shop vac. The post is welded to the outer cowl panel at...

I wasn't sure if the whole post was bad or if I could just replace the front panel. I only considered this because I wasn't sure I could replace the post without also pulling the rocker off so I started by cutting as much of the front panel off as I could. After looking at the bottom section...

Driver Door Post I always start these posts by getting out the wire wheel and scrubbing the paint off of the spot welds so I can see them. Maybe its my bad eyesight but it always helps me see them so I can try to get the spot weld drill in the right place.

I replaced the driver side door post today without removing the rocker panel, which is pretty much pristine. I wasn't sure this was even possible and I will tell everyone now that it really isn't very easy either. I will show you all how I did it just in case it helps anyone else. I started...

Pat, I read this at work yesterday afternoon and I thought "I guess he's right". So, I tried hard today

I didn't get a lot done last weekend but I was able to finish stripping the tub. This is by far the most complete Bronco I have ever owned. The wiring harness doesn't appear to have been cut into at all. It even has an almost completely intact firewall insulation piece. I've honestly never...

The one my son and I just finished

Mine in Moab a few years back

I have to rotate the nozzle (in opposite directions) on both of my tanks to actually get gas to flow. If I try to lock the lever and leave it always shuts off instantly. It's always done this, even after new hoses were installed.

After getting the grill and fenders off I went around and looked for all of the normal rust spots. The rockers are solid as are the inner fenders. The striker posts are good and the passenger front post is too. The floors are in good shape. The passenger floor panel and the driver side front...

The Tear Down Started Today Amazingly, almost every bolt came right out without a fight. I only had to cut a few in the driver side front door post. The bondo in the body seams cracked clean too. The fenders have a lot of filler on them but the grill is pristine.

Sometime between when we parked the Bronco last year and this week the left rear wheel became locked up. We weren't able to drive it at all so we drug it in front of the shop with my Bronco and then pushed it into the bay. The wheel was really locked up. After a couple of hours of messing...

Just for the record, those flares are pop riveted to the fenders and covered in bondo. There was a little mishap with one of the fenders while trying to get the bronco in the shop.

The Donor My daughter and my youngest son spent a few days with me over the holidays and we started pulling the donor apart. It is a 1998 5.0 Explorer XLT with 166K on the odometer. This thing was extremely cheap at a small dealer in Salt Lake City about a year ago when we picked it up...

I'm pretty sure they are riveted and the heads are smoothed over with bondo. I will take a picture from behind the fender and let you know.

It's a new year and time for a new build! I picked up a '76 wagon a couple of years ago while I was finishing up a build for my son in anticipation of starting one for my daughter. That first build took a couple of extra years to finish so I'm a little behind on this one. Along the way we got...

Delivery It's all done. It's a few years later than I planned but it turned out great. I delivered this to my son last night as an early Christmas present at his son's second birthday party. My grandson loves to ride in this Bronco so it looks like this project wasn't just to keep the love...