"Lil Rusty" My second Bronco

[brianstrange]

UPDATE!!!! As luck would have it, I think I hit the Trifecta (sort of) The engine temp wire is grounding out giving a false high reading at start. Also, the system holds 13 lbs of pressure, but bleeds down slow. I found a pinhole near the top of the radiator (add that to the list) It's possible that it was just low on coolant due to an air bubble. I recall only putting 2 gallons of coolant in it after the timing cover, and now I'm reading that they take 4 gallons when dry!!!!!!! I was able to replace the rotted out tailgate with a solid one another member had kicking around. I'll be looking for a nice radiator, but this one should get me thru the winter.

 

[deadfish]

is that the one you took back (indian giver)or the original ? caliper are in the correct location.need to pick up some hose to bleed

 

[tasker]

Dave? is that really you??

 

[brianstrange]

is that the one you took back (indian giver)or the original ? caliper are in the correct location.need to pick up some hose to bleed

It's not the 66. He had this kicking around. It's encrusted in surface rust!

 

[NGABronco]

Cool looking tailpipe extensions!!!

 

[brianstrange]

After dealing with a manual choke carb this winter, I quickly realized how terrible they are, and how great EFI is. Lil' Rusty is getting some jewelry.

 

[fatboy]

Wow, you will be buying sheet metal this summer the way you are going!

 

[brianstrange]

Wow, you will be buying sheet metal this summer the way you are going!

You might be right. I'd love to have the core of it solid, clean up the inside, and buzz her around at home. Unfortunately the co$t is not in the budget, so it's spare parts until then.

 

[brianstrange]

So, after 5 months, I'm happy to report that she runs great, and no hints of mechanical issues. She starts right up even after sitting for 4 weeks. I do need a radiator, but that can wait until she sees the road. Overall, it needs doors, floors, in&out Rockers, Cowl sides, and a cowl top (Thanks Randy) The drivers side is worse than the passengers side, so I'll aim there first. I've been thinking I may be better off going BroncoDesign Trail tub, but it's just not in the budget, and may never be. If this tub had some significant value as is, I'd be all over it, but what is a somewhat usable tub worth these days? I've kicked around doing a 2WD Baja street rig as well. For now, I'm thinking fix the floors, and go from there.

 

[brianstrange]

So this is officially my new low budget restoration. Off for the center body sheet metal replacement, then EFI. It should be fun, as Olivia has her eye on it.

 

[fatboy]

So this is officially my new low budget restoration. Off for the center body sheet metal replacement, then EFI. It should be fun, as Olivia has her eye on it.

Coming to NH for the work? Close to me????

 

[brianstrange]

Coming to NH for the work? Close to me????

Yes! I'm very happy about it too. I started schooling Olivia on driving a manual transmission. It's going to be one hell of a gear grinder!

 

[fatboy]

Yes! I'm very happy about it too. I started schooling Olivia on driving a manual transmission. It's going to be one hell of a gear grinder!

Fun. The work will be killer too!

 

[Slednut10]

Coming to NH for the work? Close to me????

Why? You gonna raid it for parts?;D%)

Nice, Brian, glad you're keeping it!

 

[migs]

I guess I'll update this here since "lil rusty" is in my posession at the moment as I've been commissioned to work on it.
First, let's take a look at when it first moved into my garage and when I popped the fenders and grill off. Brian did losen those bolts ahead of time, but I did have to cut one that decided to just spin. and of course it was tucked way up in the front of the fender.

So, after the exposure maybe a name change to "big Rusty" is in order?:-X;D;D

 

[migs]

I decided to tackle the passenger side floor pans first.

Here is a look at what I had to start with along with a great trick for removing a bolt where the head has pretty much rusted down to nothing, that's the body mount bolt that goes through the front floor pan.

 

[migs]

I finished cutting out the rusted metal, trimming and test fitting the new panels and the piece I made to replace that vertical section at the rear of the floor pan.
Then after grinding away all the spot weld remnants and some POR in the support channels after cleaning it's about time for some welding.

 

[migs]

Here we are after punching and drilling lots O' holes and screwed down after the final fitting. Next it's all welded up then ground down.

 

[migs]

And finally, after applying some seam sealer and a little primer... the passenger side pan repair is done.

Now it's "a lil less rusty";D

 

[dave67fd]

Top notch work as usual migs. Sure Brian will be ecstatic.