Mass Confusion Build. After 2 1/2 years It started!!

[Mike Hewett]

Another thought...if you havent already, put your dash in position. Seems like I had about a 1/2" between the dash end and door post/kick panel

 

[71massbronco]

Thanks for the input. I haven't tacked anything down yet. I only can go by what was left on the truck before and that wasn't much!

I did fit the door on when installing the post. I know the DS post is in good position. I am a little fuzzy on the exact placement of that cowl piece. You wouldn't happen to have any pics of where your cowl and door post meet would you? I have nothing to go by. I was thinking the same thing about putting the dash in to get placement. I really need to get that other kick panel in, so I can get things a placed better. Thanks again.

Edit: After some extensive searching, found the right placement for the window cowl. See above pic.

 

[HGM]

Thanks for the input. I haven't tacked anything down yet. I only can go by what was left on the truck before and that wasn't much!

I did fit the door on when installing the post. I know the DS post is in good position. I am a little fuzzy on the exact placement of that cowl piece. You wouldn't happen to have any pics of where your cowl and door post meet would you? I have nothing to go by. I was thinking the same thing about putting the dash in to get placement. I really need to get that other kick panel in, so I can get things a placed better. Thanks again.

Edit: After some extensive searching, found the right placement for the window cowl. See above pic.

I'd recomend verifying the cowl against the radiator core support as well as the door openings. I've been figting mine a bit because I had the whole front clip off when I did my cowl. Got it off about 1/4"... Good bit of work to get it back where it belongs.. Naturally, I cant find the diagram on my new computer, but a quick search for front clip measurements should find it for you..

 

[71massbronco]

Today went out and refitted the window frame cowl. As per Mike's advice, I put in the dash and everything seemed to line up with no glaring issues. HGM, if you find those measurements to front core support, let me know what they are! I had them laying around and in my zeal to keep my garage clean have been relocated to a location of unknown-ness.%) I marked some stuff off for repositioning it later. Also tweaked my DIY DS kick panel so the cowl frame will sit flush with the door post.

I am really at a stand still now for measuring and fitment until I get that PS kick cut out. So I drew it out and did some metal management so my dwindling stock will get me another floor pan, and the top of the firewall section.

I also called around today to find somebody that can roll a trough in my floor pans. Nobody has called me back, so they just may stay flat.

 

[BDAZSVT]

Here is my hinge post.

 

[71massbronco]

Here is my hinge post.

Thanks for the pic. I thought it would sit a little lower without so much gap. I assume the gap is need so the fender can fit in there correct?

 

[71massbronco]

I cut out my PS kick panel. I never cease to amaze myself on my lack of accurate measuring. Everything went good until I discovered I had over measured an inch where the post meets the kick on the door seal. Don't know how that happened but it did. Lopped it off so I was good to go.

Ok, so let the fun begin.

Trying to line up the panels. What PITA. Don't know what I did wrong but there is a HUGE gap on the PS where grill and quarter meet. It looks as though the radiator support is too wide.

Thought maybe it was the fiberglass quarter was molded wrong or had warped somehow. So I got out the original and had the same issue. Drivers side is lining up pretty good. I can't seem to get that PS sucked in because the support is too wide? I double checked the original support to make sure that I attached the inner fenders correctly. They were spot on with the original.
Decided to put the hood on to see how things would line up with the lower window cowl. Maybe shed some light on the problem. I measured from the cowl to the hood spring and was about 3/4 inch off. Looks like I need to push the radiator support back. This may solve the grill being too far forward, but it is now not in the same position as the original that I have. Thankfully, I haven't welded anything so this is easily adjusted.I don't know if this will help with the PS gap. I am open to suggestions or ideas.

 

[HGM]

HGM, if you find those measurements to front core support, let me know what they are!.

Had to look for them a bit, but here's the best I've been able to come up with. Not perfect, but it will give you a good idea.. Also, in the Bronco Graveyard catalog, they've got a couple of decent measurement diagrams in there.

 

[71massbronco]

HGM, Huge thank you!

 

[71massbronco]

I finally cut out my lower cowl panels to make way for the replacements.

Ok, this was driving me crazy with front fenders not lining up with the grill.

I took the measurements HGM gave me and got them to correct spec. Then put the fenders on and back to square one.

Found two problems. My PS is leaning a little. The second more disturbing problem was unexpected.

After pulling the panels back and forth, getting them to exact specs, then putting on the fenders to check the fit, it would all go out of whack. Then it occurred to me, that I never checked the new radiator support see actually how wide it is. I measured it and it came in at 57 1/2 inches. I went to my original and measured it. Low and behold, it came in at 57 inches. That explains the 1/2 offset on the PS. So now I have to shave 1/4 inch off of each side of the radiator support. At least now I know what the problem is. Man what a relief! It was absolutely driving me bonkers. I guess the moral of the story is, make sure you check the measurements on your replacement parts!

Edit: Turns out that since I was bending the tape measure to get the measurement of the already placed support, it only looked like 57 1/2. It was actually the same width as the original.

 

[HGM]

After pulling the panels back and forth, getting them to exact specs, then putting on the fenders to check the fit, it would all go out of whack. Then it occurred to me, that I never checked the new radiator support see actually how wide it is. I measured it and it came in at 57 1/2 inches. I went to my original and measured it. Low and behold, it came in at 57 inches. That explains the 1/2 offset on the PS. So now I have to shave 1/4 inch off of each side of the radiator support. At least now I know what the problem is. Man what a relief! It was absolutely driving me bonkers. I guess the moral of the story is, make sure you check the measurements on your replacement parts!

I know the feeling well.. That's the same type of thing I ran into while building my front clip.. Part of the reason I moved to the rear for a change in scenery.. Glad it all worked out!!

 

[71massbronco]

OOOOk. Think I found one of the reasons this fender/grill gap thing is baffling me. I have screwed the radiator supports to the inner fenders. The screw heads are preventing the fender from sucking up to the inner fenders like it is supposed to. Will remove the screws soon and weld to fix this (uhhemm) error. Should help the problem a little bit.%)

Cut out the lower cowl from the last of the sheet metal stock I have. I decided to cut the four feet section in half so I could use my brake that restricts me to 30 inches or less. I zig zagged the cut. Heard that it is stronger this way when I reattach them.

Also decided to take the dimples from the old section, cut them out and tack them to the underneath for strength. Seemed to work pretty good. While cutting them out, had a first...Frickin' cutting wheel tried to eat my cowl! I still don't know how this happened just glad I didn't lose an eye (had the eye protection on) and had a good grip on the grinder.

Then I set out to attach the panel to the firewall. Also I am ditching the underhood intakes so I built a filler for that area. I think after this, the body comes back off and I am full steam ahead for the reassembly, and mechanics.

 

[fatboy]

Looking Good!

 

[stupidboy]

You'll be needing one of my Hoods soon!!;D

 

[dave67fd]

That first pic is scary. My cowl area will need all that same treatment at some point. I'll know who to call for help.;D

 

[71massbronco]

That first pic is scary. My cowl area will need all that same treatment at some point. I'll know who to call for help.;D

I know, kinda freaked me out. Was a DeWalt disc, not my cheap Chinese backup discs, of which I am now using. Must have caught it just right. Really, I want to get up there, just my wife works Saturdays and I have four young sons. Someday I will get up there. I will bring the brake and my cutting wheels, all I need is 18 gauge stock and we are all set!

 

[71massbronco]

You'll be needing one of my Hoods soon!!;D

If it includes front induction, I'm in.

 

[dave67fd]

Really, I want to get up there, just my wife works Saturdays and I have four young sons. Someday I will get up there. I will bring the brake and my cutting wheels, all I need is 18 gauge stock and we are all set!

We'll have to wait until the warmer weather returns and your not so busy. Sucks that I'm pretty much at a stand still untill it returns anyway.

 

[71massbronco]

I hear ya. May be starting a new job come March (in addition to my old one). But we will hook up some weekend.

 

[71massbronco]

I am having a ton of alignment issues. Due in part of my DIY panels, old parts from another truck and a tired body, so I decided to put the body together as much as I can so everything is aligned before I take the welder to it and make it solid. I even put the top back on to see how the new windshield frame would line up. As you can see from the pics I have alot of issues that need to be addressed so it will look top notch.

The doors, (they're killin' me) need new pins in the hinges as they are sagging beyond what's acceptable. Scraping the bejeesits out of my rockers, they need to be refreshed. Front grill alignment I think will be solved when I tighten up the inner fender to the radiator support.

The extra rust free door Russ included in the sale had a big ol' dent in it and was pushed out on the bottom, so now I know why he included a fifth door. That's right, this EB came with three extra doors, and looks like I'm going to need them all.

Any advice or tips to make this better are appreciated!


I pulled it out of the garage so I could turn it around to put the cap back on. Left it in the driveway and the wife saw it for the first time looking like something that could be driven. Her reaction was "Wow, that's lookin' cool, when will it be ready?" This is a good sign to get another.