Early or late core support?

[jckkys]

My '77 core support was badly mangled in a front end collision. WH reproduction is the most accurate late version. It looks identicle to the'77. I have a clean rust free '68 core support but I can't see how the Saginaw power steering gear can fit behind it. The radiator opening is about 4" narrower on the '68. The radiator air flow may be reduced, tho I can't tell. Can I make the '68 work? Is it worth trying? Or should I just get the WH support?

 

[bk005]

I just put one of the repros in my 77, it took just a bit of trimming for the gear box. Decent enough part. Wonder if you could cut an opening in the one you have and box it in for the gear box?

 

[pa69broncoguy]

Im sure you could make the 68 core support work, its just how much effort you are willing to put into it? You could most likely pull or cut off the recess for the power steering box from the 77 and rework the rad hole if needed. Usualy new is last resort for me but I have more time than money so it takes a lot before I pony up the cash for new.

 

[jckkys]

The power steering gear box on the '77 core support was mangled in the wreck. It would be easier to make a pocket in the '68 core support in front of the the steering gear. It looks like it would only need about 1/4". When Ford redesigned the core support in '73 they put more effort into the widened opening than the box for the PS gear. The sheet metal could have been simply stamped to clear the PS gear. Opening the radiator intake seems to be the primary reason for the redesign. It often goes over 110 degrees here in the summer and blocking the radiator isn't a good idea. I learned that, when I tried to mount an engine oil cooler behind the grill, hoping to help the cooling. It did just the opposite. If I cut the '68 opening wider, the lower radiator mount will be greatly weakened. I'm not a paint and body man, so the cost of having all the work on the '68 done may make the WH support a better deal.

 

[thegreatjustino]

Think about all of the people with 66-72 Broncos who have converted to power steering over the years. Do you think all of them swapped their core support too?

The notch for the steering box is hit and miss. I've converted to stock PS without having to do a thing to the core support and I've sometimes had to notch the bottom part of it in order to move the box forward enough on the frame to make the mounting holes line up.

Either way, the earlier core support will be fine. If you're running the original air cleaner with the snorkel going to the fresh air inlet in the core support, the '68 won't have that opening either.

 

[Rymadd]

Curious what you guys are talking about with the power steering hitting the core support? I have had both a stock power steering and a 4x4x2 power steering box and they both fit fine. I do have a notch in the inner fender cut out by the PO but nothing on the core support

 

[thegreatjustino]

The bottom of the support sometimes interferes with the longer snout of the PS box. Depending on the Bronco, you sometimes have to modify it. I had to cut the pictured notch in the core support of my '69 to get the box to slide forward enough to line up the mounting holes.

 

[jckkys]

I'm sure I stated that the '77 was mangled in a wreck, so I have no way of knowing if the box on the '77 was needed. I do know it's there and logic indicates it's there for a reason. My post was to find out what others had encountered doing this combination. My next question is concerned with the effect of a 4" smaller radiator opening. Again as I stated the majority of the changes in the '73-'77 core support allow a larger radiator opening. Is it worth pursuing the late version in terms of improved cooling? I'm glad to know the PS box doesn't rule out the '68 core support.
I've seen incredibly stupid things done to EBs, so I won't assume anything.

 

[broncnaz]

I've run a 67 tub with the smaller opening and factory power steering had to clearance the lower ridge on the core support(similar to the pic) a little for clearance but thats about it. The later kickout probably wasnt really needed but they made sure there was extra space for the PS box.
I never had cooling issues with the smaller opening core support and I used to daily drive in tucson traffic in the summer and wheel in the summer as well. Although it would probably be fairly easy to open up the opening while you have things apart. More airflow definetly wont hurt.
New core supports are spendy and unless you are trying to stay correct. Id just use what you have.

 

[jckkys]

The radiator opening is narrower because the rib that the radiator is mounted to, is continuous top to bottom. I hesitate to cut it out, without welding a rod top to bottom to retain some structural integrity. The core support mod I'd love to see is a bolt in center section on the top to make water pump replacement and other engine bay work easier.
I am doing a frame off so why not do the body, at least, correct. I've wrecked two Broncos so I don't need to build one to trash it. Been there done that. This time it will look good, be quiet, and comfortable. Id like to drive it to Bronco events across the country.

 

[broncnaz]

Yeah I was thinking that the supports may have been in the way so a larger opening was not really possible without cutting them out. Of course the later models had shorter support brackets with reinforcing brackets moved outwards. So adding some reinforcing after cutting would work. Or try your center core support mod idea although Im not sure how thats going to be much better as the radiator comes out easy enough when anything needs to be done and provides enough room.

 

[jckkys]

Until I learned to put thread sealer on the long water pump bolts I broke a couple off trying to get them out. Even after removing the grill and radiator, they were a PITA to drill out. The top cross piece of the core support was still in the way. If a few bolts held it in, and removal were possible, a lot of jobs would be easier.

 

[broncnaz]

Thats always the case when something breaks. Theres almost always something in the way.