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Replacing Floor Pans = Frame Off Restoration!

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
I bought the ole girl April 2018 and it was my first bronco. The family and I loved every minute we got to spend in her but I felt it was time to give her a makeover... Little did I know, she was a pig with lipstick on. This journey started out with plans to replace the floor pans, install a fresh 351w, ZF5 tranny and clean up the engine bay. After removing the engine, tranny, etc and one of the floor pans, I had this crazy idea of taking her to the ground! I ran into a ton of rusted metal and figured I'd give it a shot. YOLO! :) That's how my frame off restoration began...
 

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MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
After pulling the enigne, tranny, wiring, etc... It was time to get lifted!
 

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MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
It was pretty gnarly when I pulled the outer fenders off. The PO also had diamond plate over the kick panels... Or lack there of. They were basically gone. He put some kind of roof mastic crap all over it. It was a PITA to get that stuff off. Out with the old and in with the new!
 

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MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
Wow! You dive right in. Still planning 351 and zf?

As all builds generally go in a different direction than planned, I decided to go off the deep end... I tore down the 351w and found a bent rod. It wasn't the end of the world and the block/cylinder, head, etc all looked great. I'm thinking they hydro locked it at some point as I didn't' see any internal damage other than the rod. Even the piston looked great. I was on FB that night and a guy posted some BC Bronco headers for a Coyote for $400. I've been wanting to put one in and I guess that was my sign! haha.... I went with one out of a 15' F-150 that had 1k miles per the salvage yard. (not sure how much of that I beleive :) ) and a 6R80 trans. I have a 77' that will make a great home for the 351w/ZF5 when I build it this fall/winter.
 

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MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
The frame was in pretty good shape and I only had to cut one small section out. I decided to clean, degrease and etch it and use POR15. It seems to be a pretty good product. I was nervous as all get out that I'd get some one me. I've heard it doesn't come off easy. I went with the full white jumpsuit and mask! I freaked my 3 year old out when he came into the shop :)

I took the front, rear and transfer case to a local shop to be cleaned, painted and all internals replaced. I went with 4.11 gears.
 

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jmhend

Bronco Guru
Joined
Dec 25, 2007
Messages
2,733
It was pretty gnarly when I pulled the outer fenders off. The PO also had diamond plate over the kick panels... Or lack there of. They were basically gone. He put some kind of roof mastic crap all over it. It was a PITA to get that stuff off. Out with the old and in with the new!

Are you planning on doing seam welds or plug / rosette on your panels?
 
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MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
Are you planning on doing seam welds or plug / rosette on your panels?



Little bit of both. I put plug welds about 1.5” apart anywhere I could and seam welds on the perimeter. Here are a couple pics showing what I did.

0fb8c64cc3693209270394ae10142add.jpg


138a5f6c18a804e8fc25f5bcb34cb712.jpg



Sent from my iPhone using Tapatalk
 

jmhend

Bronco Guru
Joined
Dec 25, 2007
Messages
2,733
Thanks I am still gathering parts but always curious on what others are doing
 
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MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
All sheet metal is done. I had to rebuild the air box area as it was shot. The rest of the cowl and the firewall were in great shape. The rear wheel wells had some rust which I cut out and replaced with some new sheet metal. Upol has a product called Fibral Lite that I’ll use around the new panels which will blend it in with the existing metal. It’s a great product. Most paint shops carry it.

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Sent from my iPhone using Tapatalk
 

ngsd

Contributor
Bronco Guru
Joined
Mar 2, 2019
Messages
2,527
I like the angle iron bracing. Getting ready to do the same. Question, I don't have a 2 post lift but I have an overhead hoist. Do you think the bracing is solid enough to lift the body up if you used points of of the bracing or do you think there is too much flex there?
 
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MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
I like the angle iron bracing. Getting ready to do the same. Question, I don't have a 2 post lift but I have an overhead hoist. Do you think the bracing is solid enough to lift the body up if you used points of of the bracing or do you think there is too much flex there?

I think if you ran another angle iron from side to side (about where you would sit) and another closer to the back (behind where the rear seat would be) you would be fine. There's a guy on here from AZ that did that and was lifted it with an engine hoist and it was fine. I'll try and find the post for you.
 
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OP
MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
I like the angle iron bracing. Getting ready to do the same. Question, I don't have a 2 post lift but I have an overhead hoist. Do you think the bracing is solid enough to lift the body up if you used points of of the bracing or do you think there is too much flex there?

Here is the thread I was referring to. He also built a really nice body cart too.

https://classicbroncos.com/forums/showthread.php?t=217635&page=3

https://classicbroncos.com/forums/showpost.php?p=2246039&postcount=32

This was done by AZ73. He did a fantastic build.
 

sprdv1

Contributor
REBEL
Joined
Mar 8, 2007
Messages
81,734
Coming along well there boss... Jealous you so close to some white castles :)

U should keep eye out for the group get togethers out your direction and go meet folks.

It'll pop up in Chat section
 
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MidwestTexan

MidwestTexan

Jr. Member
Joined
Apr 1, 2018
Messages
92
Coming along well there boss... Jealous you so close to some white castles :)



U should keep eye out for the group get togethers out your direction and go meet folks.



It'll pop up in Chat section



What’s up Dave? I’ve met a couple guys from MOEB. Great group. I’m looking forward to going on a ride soon. I’m actually only about 2-3 weeks away from completing this build. I was so focused on trying to get it done before summer I didn’t get a chance to start my thread on here until now. I’m waiting on parts so I’m free until Wednesday. Haha... I started tearing her down on 1/15/19.

Come on up and get you some Whities! It’d be great to put a face with a name.


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