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Morgan's 1969 Bronco

1969miller

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New Member
Joined
Jan 18, 2022
Messages
27
Loc.
Elk Grove
I've owned this bronco for about a year now but since progress is finally moving I figured I'd make a build thread.

I've built a few different rigs over the years, and worked in the offroad industry for about 7 years now. in September of 2020 I started at your favorite Bronco parts house and was bitten by the bronco bug. Within 7 months I had found my project.

Drove from Galt, Ca to a little town called Morton, WA to pick up my bronco. She was rusted out, had been rolled once in her life, had no paperwork, and the owner was not sure what year it was.

Came with an NP435, a J shift Dana 20, a hodge-podge D44 HP with D30 kingpin outers, and a falcon bench seat.

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Found a way through all the red tape and have gotten it titled and registered in CA!

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Decided the tub was too far gone to save, so it got sold.

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While I continued to tear things apart and sell them, I picked up a very very low mileage Explorer 5.0, an incredibly cheap NV3550, and a set of full width axles.

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1969miller

1969miller

Contributor
New Member
Joined
Jan 18, 2022
Messages
27
Loc.
Elk Grove
Made some V8 engine mounts to replace the 170ci engine towers I cut off the frame

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Came up on a great deal on a protofab bumper at the WH swap meet.

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Opened up the engine to find it was immaculate. Put on a dual sump pan and a new pickup and was good to go! The stage 8 locking bolts were great quality.

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The frame being sent off to sandblasting

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So far with what I have sold, and the deals i've found on the new parts going in, I am net about $3000 into this project after registration. More to follow as it's on my trailer being towed home today.
 

904Bronco

Contributor
Bronco Guru
Joined
Sep 28, 2004
Messages
5,276
Loc.
San Martin, CA
Very Nice .
You must work at WH's based on all the pictures in the shop?
What a great place to restore a Bronco with all that knowledge and "er ah" parts available.
I look forward to the continuing story...
Doug.
 
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1969miller

1969miller

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New Member
Joined
Jan 18, 2022
Messages
27
Loc.
Elk Grove
Got the frame off loaded and into the garage.
Yes I put on my eye protection shortly after this photo..
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Went straight to work cleaning the remaining bits of the 6cyl mounts off the frame. Decided I don't like the fitment of my fabbed v8 mounts so I'll be getting the stamped version from wild horses. Next I went to cutting out and redoing most of the factory welds. I'd thought I got the Friday afternoon or the Monday morning made frame but turns out they're all like that. Porosity in the welds and bits of wire everywhere.
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Tried many times to weld nuts to the broken clutch equalizer bolts with no luck. Probably will have to drill them but I'll let them soak in pb blaster overnight and try welding once more.

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Pa PITT

Contributor
Bronco Guru
Joined
Jul 15, 2005
Messages
11,090
Loc.
Stephenville
SO I too was thinking your pulling that tub off.
So what's YOUR PLANS to replace it with ...
Keep posting
 
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1969miller

1969miller

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New Member
Joined
Jan 18, 2022
Messages
27
Loc.
Elk Grove
Hopefully build a new one that's half decent. My logic in selling it was it wasn't worth it to put new steel with half good steel when i would be replacing almost all of the panels anyway.
 
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1969miller

1969miller

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New Member
Joined
Jan 18, 2022
Messages
27
Loc.
Elk Grove
Started mounting the new motor mount towers last night. Got them tacked in and after double checking a few frames at work i should be ready to burn them in tonight.
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Then moved onto the spring hangers. Starting with the rear then Ill tackle the front. might be a rolling chassis sooner than I thought!

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jamesroney

Sr. Member
Joined
Sep 11, 2007
Messages
785
Loc.
Fremont, CA
Now is the time to decide what steering box you are going to run, and make the appropriate mods to the frame now...before you do your paint/powder.

If you are doing the factory box, make sure that you have enough space for the nut and washer on the inboard side where you just welded.
If you are doing a 4x4x2 box, make sure you add metal to support the new nut and hole. Also will want to notch the core support bracket.

Nothing worse than welding/grinding on fresh paint.

And stop playing around with the broken off clutch pivot bolts. Center punch, drill, and re-thread them.

Looking great!
 
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1969miller

1969miller

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New Member
Joined
Jan 18, 2022
Messages
27
Loc.
Elk Grove
Not many updates. Slowly chipping away. Plated over the body mounts. Didn't want to graft in the steel as this won't be a restoration but more of an offroad build. My plans for a 1in body lift will now be a 1.125in body lift.
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Cutting off more and more. Front leaf spring hangers are removed, just need to go get a better grinding wheel to take down the big stuff, tired of burning up flap wheels. Here are the rear bump stop mounts. Not too bad underneath.
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This is probably the worst spot on the frame where water collected and rotted away a bit.
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And my next can of worms about to be opened.. not pleased with the crappy welds on the frame seams. So it's looking like I'll be welding the whole frame front to back on each side. Little stitch welds to keep it from warping. Fun stuff..
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I'm in the process of making a jig to build some extended radius arms then I can get the front axle under the frame.
 

DirtDonk

Contributor
Bronco Guru
Joined
Nov 3, 2003
Messages
43,179
Be sure to build the jigs for volume so we can sell us some radius arms!
The factory welds were never highly thought of, even when these were new and we weren't as sophistimicated as we are nowadays. The big bits of MIG wire hanging out of some of the welds were always good fodder for ridicule around the garage at beer time.
Can't wait to see some real welds show up in their place on yours!

Paul
 
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