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Chopped, slammed, bagged, tubbed, lowered floors, 418 w/blower, 6r80, 1/2 cab, Bronco Hot Rod

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nvrstuk

nvrstuk

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Just a Bronco driver for over 50 yrs!
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9,336
[HIJACK]
But they're so cute! I'm sure they just need a little affection, ear scratches, cat treats and they'll be fine!

I blame Walt Disney for that attitude.
[/HIJACK]
Exactly right TS. "Wet Siders" (Seattleites as we call them) don't think of them as much more than that. Every once in a while a hiker or mtn biker gets mauled to death and loses his guts to one but they love to hear about how many there are in our State now.

A local State Representative introduced a bill last winter to trap and relocate 8 of these cute furry kittys and take them over to a high income snooty Island in the bay across from Seattle and release them so they could "experience them" like we do... yeah, they thought he was joking but he wasn't. :) We were all for it! lol
 

ntsqd

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Upper SoKA
Apex predators didn't get the memo that humans are at the top of the food chain. They just think that we're tasty with a little ketchup.

I know someone who lives on one of those islands, He likely fully supports that idea!
 

Yeller

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Rogers County Oklahoma
We have had 2 confirmed Carcajou-, wolverine sitings here the past couple years. Holy cow- don't mess with them!!!
Buddy who is a County Sheriff has a pic of him holding one up as it was hit by a car of all things :(
I trapped one when I was a kid... nasty mean critters. Honey Badger aint got nothin on em. Supposedly we have some of those here....
 

BronCowie

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Apr 24, 2007
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Vancouver, WA
We have had 2 confirmed Carcajou-, wolverine sitings here the past couple years. Holy cow- don't mess with them!!!
Buddy who is a County Sheriff has a pic of him holding one up as it was hit by a car of all things :(
I would not like to tangle with one of these bad dudes...

carcajou-wolverines.jpg
 

ntsqd

heratic car camper
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Upper SoKA
I dunno, a .338 Lapua at about 500 yards (closest I'd want to get) would make a believer out of one. :)
Unless you're of the over-kill persuasion, then we're looking at a .375 Cheytac. :) :)

Somehow I'm thinking "Honey, I NEED this .375 Cheytac in case carcajous / wolverines invade suburban Upper So. Ca." is not going to fly.......
 
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nvrstuk

nvrstuk

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Just a Bronco driver for over 50 yrs!
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Shipping on the tunnel cover is appr $250, probably more the guy said. Ouch.

Guess I go option "X or Y". lol
 
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nvrstuk

nvrstuk

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Just a Bronco driver for over 50 yrs!
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I can call them tomorrow. They were the guys that wanted to charge me $5,000 for 4 bends and two sticks of frame rail tube tho. lol

I got a screaming deal tho on two hard bends for $20. Not using them tho. They are 110 miles away, been there and was quite surprised by their facility.... probably nice location in the '50's, not such a nice area anymore. :(

I just went thru their catalog and didn't see anything either. I'll call. Got one local source that might be able to help me out. Check him tomorrow also.
 
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ntsqd

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Had to look up where that is. Saw some of that area once, in 1986. Wasn't pretty then.
 
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nvrstuk

nvrstuk

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Just a Bronco driver for over 50 yrs!
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Didn't call Art Morrison but I did get a couple hours in the shop. Floor is gone. Going to a friends tomorrow to see what sheet metal work he can do.
 

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1970 Palmer

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It will be easier to build a new floor, rather than trying to modify the stock floor to fit your new frame, IMO. If you have access to a 48" sheet metal brake, a 24" to 36" slip roller, and a bead roller you in business. The suppliers around me will give you one free cut when you buy a full sheet or stick of metal. If you do not have access to your own shear, it helps to have them cut your largest piece, then you can whittle it down to your final size.

I think I would fully build, at least "mock up" the new exhaust system before you fabricate the new floor.

The hardest part of building a new exhaust system in a build like yours is figuring out how you want to hang it. Designing and fabricating the hangers is very time consuming. Keep in mind that the exhaust system grows in length when it gets hot. Your exhaust mounts need to be designed to allow for the length growth.
 

ntsqd

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I've been using these: https://www.summitracing.com/parts/wlk-35780 and these: https://www.summitracing.com/parts/wlk-35460 for exhaust hangers on projects going clear back to Patch, the Wonder Yota. I orient the rods such that they are parallel to the exhaust tube and when cold push against opposite sides of the rubber piece so that as the system grows with heat the rods just pull back thru the rubber. This gives me about 2" of thermal growth allowance. They are a little space consuming, recommend buying two rods and a rubber piece for mock-up before commiting, but I really like them. Lots of compliance with no noise transmission.

I have discovered a downside to these and that is that you can't make the exhaust tube side rod too short or it melts/burns it's way thru the rubber part. :( Didn't help that the one that suffered that fate is about 12" downstream from the cat. doh!!! I re-made that hanger to have more length by picking up the tube from the bottom rather than the top and it's been working ever since.

A concept that MISF came up with, that I've been using for 20+ years, is to make the exhaust system come out in sections. We use 3 bolt flanges, but do NOT butt the tube ends together. the upstream flange is set about 1/2" further upstream from the end of the tube. the downstream flange has it's ID opened up to fit over a piece of exhaust tubing that has been expanded to be a slip-fit over the upstream tubing. The downstream flange is welded to upstream end of the slip-fit. I've never used a gasket with these connections. I have used high temp RTV with good results.
I used to ask for the expanded section to only be 3/4"-1" long, but now I just get as long of expanded section as I can and cut it into ~3/4" long pieces. Bolting the expanded piece (with it's flange welded on) to the upstream flange gives a nice 'socket' to plug the downstream tube into. When ready it's easy to just weld the downstream tube into that 'socket'. I try to buy flanges with dedicated holes rather than slots. Even with the now more common V-Band clamps for exhaust systems I find that I prefer the 3 bolt flanges. They do take longer to make, but they fix the rotational location where the V-bands don't. I used to have a SW generated jpg of this, but I'm not finding it. Should I make another one?
About the bolts holding these joints together. Most can't or won't believe me when I tell them to use a carbon steel bolt with flat washers only, and a Brass nut. You won't need lock-tite or lock washers or anything else. Just take the bolts up to snug and drive it. They do not come loose. In 20+ years I've never had even one nut work loose.
 

1970 Palmer

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I agree the brass nuts do work great on exhaust headers and manifolds! Just snug them up, don't overtighten.

The last exhaust system I built was for a 32 Roadster. I knew I would be having the system and the headers ceramic coated. So I went to my coater first and talked it over with him. He told me his high temp ceramic coating oven would only accept parts up to five feet long. I built the system in three "five foot long" sections. I had it done in a satin black inside and out and it looked like new after five years of driving. I really think the coating helps with the radiant heat.

I'm in love with the stainless V-Band clamps. They work very well, allow 360 degrees of micro adjustments and do not move or leak after you snug them up.
 

ntsqd

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Upper SoKA
Slip-fits and much more than paint on exhaust (I'm cheep and use bbq paint) require some consideration or they don't slip very well.

The V-Bands are nice, until you don't want that adjustability or can't swing their cost. The solution gets kinda tricky and requires a mill. We used one on a prototype patio heater that was mounted on a '?' shaped tube that had combustion air blown thru it and we had the make the tube ship in two pieces. V-Band with an anti-rotation key was our solution.
I think it was Columbia Mandrel Bending that had the best price on them at the time that I looked. Shipping to Casa de nvrstuk wouldn't be huge from them.
 
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nvrstuk

nvrstuk

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Just a Bronco driver for over 50 yrs!
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I've bought several boxes of mandrel tubing from Columbia Mandrel over the decades. :) They changed their purchasing and such so it's not as convenient but beats $500 for small jobs from our only local (& who used to be inexpensive) custom muffler shop.

I love V band clamps also.

I have my frame and muffler hangers all figured out for this build - until I get to the rear axle, then it gets a little bit tricky and I'm undecided. lol I need headers that will breathe and they are dumping outside the frame at the part-line btw the block and trans adapter. 1 3/4" primary min with 3" collectors is what I've figured for air flow and I can't find a single one... hate to spend $500-800 plus on some, cut them all up and then spend another $300 plus to ceramic coat them inside and out. I don't have any way to TIG stainless so after modifying them with a MIG I would need them powder coated if they started out as a SS header


I am going to build my floor and then anchor my roll cage or 3 pt seat belt harness bar to it. I have all my measurements for the floor down to a 1/4" ( until I change the crossmember dimensions) and I will experiment tonight with radiusing 3/4" x 4" rect tube. I will put multiple relief cuts in it and see what the "radius" looks like. Lot of cuts/welding/grinding but I only have one crossmember that needs to go over the tunnel. The other 3 will just be driveshaft tunnel hoops.

I am 100% undecided on the tunnel being rounded or with 45-60 deg bends like the stock Bronco has. I think the rounded tunnel and driveshaft tunnel look more stylish, hot rod like but the primal looking flat pcs with 45-60 deg bends is what it came with (not that I care) but is it harder to do carpet over rounded panels or square cut corners??? I"m clueless.

I called Art Morrison today and no luck. They recommended a race shop who uses tubing which I'd already thought of using but I would like to not lose another 1/2" of space surrounding the tunnel and driveshaft. I have an 1 1/4" die. I could use rect tube from the body sides to the tunnel and then weld two pcs of round tubing to the rectangular tubing and bend it over the top for a nice radius. Weld sheet metal between the rd tube and it would look pretty clean... maybe...

Long post without pics... I apologize! lol
 
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ntsqd

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Upper SoKA
Dump out the sides just in front of the rear tires?

About 13:60 ->
Can build it faceted like stock using 1/2 X 1/2 square tube to build a frame, or can use the same technique to build it rounded using something like this: https://www.harborfreight.com/compact-bender-38470.html by making some bending dies out of some large OD pipe with a couple of straps welded across the center to locate it.
 
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nvrstuk

nvrstuk

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Too loud and they would have about 2 1/2" clearance to asphalt.

Easy to dump there and try it tho. My goal is quiet (relative term) in the cab and loud when I romp on it. Have that now but with a windscreen from the top to the floor it doesn't break any sound. Wind yes, sound no. Wish I could post a video of me at the sand drags.

My wife can easily hear me 1 plus mile away with a quick take off when she's letting the dogs' in/out at night. She's commented about HS kids... lol
 
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nvrstuk

nvrstuk

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Apex predators didn't get the memo that humans are at the top of the food chain. They just think that we're tasty with a little ketchup.

I know someone who lives on one of those islands, He likely fully supports that idea!
Yeah, JL's on an island that we used to shoot rabbits by the truckload. Folks had wooded acreage there forever. Used to fish all around JL's island back in the day! :) Got a LOT of stories from screwing around that island. lol
 
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nvrstuk

nvrstuk

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I'm still watching the video you posted.

1970 Palmer- I do have access to those pcs of equip as of yesterday. :) Rookie operator but it will look better than not using the proper equipment.

Course I need to order tubing for my floor crossbraces, hopefully next Tuesday they can get it so I can pick it up local rather than have to drive 100+ rd trip.

I have lots to do so if I can put a full day in I might have some pics to show for it. I"m going to mock up ride height with taller tires so I can get some sidewall and 11+ inches of width w/o running rubber bands.
 

1970 Palmer

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Based on the exhaust system that was originally in my 32 High Boy, one thing you do not want to do is have the exhaust exit and end in front of the rear axle facing down because of the interior drone noise. Building in a X-pipe, or at least a H-pipe is well worth the extra time.

I found a You Tube video on The Hamb this week of a Canadian fabricator doing a "90 degree hard bend" in a 1" by 2" by 1/8" rectangle tube. It would work perfectly in your flooring application. Basically, he cut out two circle rings out of 10 ga. welded in a 1" spacer, and then cut the donut into quarters. He welded straight sections to the quarters and ground it smooth. It looked really nice. It's always interesting how Hot Rodder's can fabricate things when they do not have the access to the expensive tooling what would be used in a large production run.
 
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