Project: 76, Orange Special Decor

[Shimmy]

thanks for sharing these pics too! i always wondered what additional shaving, trimming would be needed on these JD panels.

 

[gnsteam]

Tonight I installed the cover plate. That covers up the hole in firewall, were the ECU once was. The cover plate also supports the heater hoses bulkhead fittings. And the ARB, diffs, trans, and transfer case breather lines.

I also finished the heater hoses install with the Vintage Air by-pass tube. The "H" tube by-pass fitting can be seen in the photo above. Here is a few more pictures.

 

[904Bronco]

It gets busy back there real quick! Nice job.

 

[gnsteam]

Tonight we finished, fitting up the A/C and heater hoses. Under the dash to the evaporator. Then we Clock marked all the fittings to the hoses. And removed all of hoses from the interior side and engine side. Tomorrow its off to a hydrolic shop for crimping. Here is a picture of the heater hose routing, under the dash.

 

[gnsteam]

Heres last weeks progress, with the help of Bruners4. I was able to borrowed an A/C, hose, crimp tool. So now all of the A/C hoses are finished, and completely installed in the engine bay. We also hooked up he P/S gear box, return hoses, through the P/S cooler. As well as the transmission hoses. Also through an auxiliary cooler and radiator. And you will note. The radiator, shroud and fan are installed. I hope for the last time.

Yesterday, I temporarily installed the steering column and brake pedal assembly. And I started insulating the interior side of the firewall. I'm using Siless brand sound and thermal insulation. Along with a firewall insulation kit. That I bought from Agaso Outdoor. I will post a picture of the kit next time.

With the long weekend. I should get a good amount of time in the garage today. Have a great Labor Day.

 

[DirtDonk]

You too! Are you planning to put a lot of that sound/heat barrier stuff on there? Hope so.

 

[gnsteam]

You too! Are you planning to put a lot of that sound/heat barrier stuff on there? Hope so.

Yes. Today I finished covering the entire firewall. I also have a firewall insulation kit. That I purchased from Agaso Outdoors. I will post pictures of the kit this week, as I proceed.

 

[gnsteam]

Here are the pictures I promised, of the firewall insulation kit. That I purchased from Agaso Outdoors. The kit includes five pieces of Boom Mat sound damping material. The section for the drivers side was distorted from shipping. So I only used the three, pre cut sections of the mat. That fits the center section of the firewall. I already had a good supply of Siless brand sound and thermal mat. So I used this mat material for the majority of the firewall.

The Agaso kit also comes with a layer white, bat insulation.

And a final layer of faux leather looking material. Backed by a dense foam material. This layer of material is rather heavy. And looks great.

Heres a few pictures of the first layer of insulation applied.

 

[Got4wd]

Heres last weeks progress, with the help of Bruners4. I was able to borrowed an A/C, hose, crimp tool. So now all of the A/C hoses are finished, and completely installed in the engine bay. We also hooked up he P/S gear box, return hoses, through the P/S cooler. As well as the transmission hoses. Also through an auxiliary cooler and radiator. And you will note. The radiator, shroud and fan are installed. I hope for the last time.
View attachment 949865
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Yesterday, I temporarily installed the steering column and brake pedal assembly. And I started insulating the interior side of the firewall. I'm using Siless brand sound and thermal insulation. Along with a firewall insulation kit. That I bought from Agaso Outdoor. I will post a picture of the kit next time.
View attachment 949869

With the long weekend. I should get a good amount of time in the garage today. Have a great Labor Day.

What is the plastic box on the brake pedal?

 

[gnsteam]

What is the plastic box on the brake pedal?

Hello Got4wd. If I am understanding your question correctly. It is a feature of the hydro boost upgrade that I am doing. You can see a full explanation and pictures of the bracket assembly, at post #230. In this build thread.

 

[.94 OR]

Nice looking padding.
Will the tunnel be insulated in a similar fashion?
Will that affect how the flooring fits?
Will you be using something like a nutsert for transfer case boot installation? I've always hated trying to find screw holes through thick padding.

 

[gnsteam]

Nice looking padding.
Will the tunnel be insulated in a similar fashion?
Will that affect how the flooring fits?
Will you be using something like a nutsert for transfer case boot installation? I've always hated trying to find screw holes through thick padding.

Hello,

Yes, I will be insulating the tunnel with a similar, Siless product. This product is 200ML thick. And it features a sound dampening layer, plus a thermal layer of dense foam. And yes, that will add thickness to the floor. But I don't think it will have much of an affect on the carpet installation. I do have a Tom's Offroad, premium carpet kit, with insulation pad to install.

Yes, I do use nutserts where ever possible. And this would be a good application for their use. I still need to enlarge the floor opening, for the Twin Sticks. And I will be installing a Lokar floor shifter for the 4R70W transmission.

Thanks for the questions.

 

[gnsteam]

Back to working on the Bronco last night. After a hectic week of work and a much needed week off to visit the kids in Colorado.
Not much to show in pictures. But I continue work on the firewall insulation. And we opened up the trans tunnel for the twin sticks. I'm a little surprised by the height of the shifters, just under 12". Floor to top of knobs. So tonight I installed the new driver seat for a little testing. The height of the sticks actually seems OK. What do you all think? It was also the first time sitting in the Tom's OffRoad Premium seat. Feels pretty good as well. More to come. Have a great weekend.

 

[gnsteam]

Last week, I finally finish the firewall insulation. As mentioned before, this is a combination of Siless sound/thermal insulation. And the Agaso Outdoors, firewall insulation kit. The installation isn't hard. Just very time consuming.

You can also see in the pictures. We installed the brake pedal assembly and the Vintage Air heater hoses and valve. Along with the brake pedal assembly. On the other side of the firewall. We installed the Ford Super Duty hydro boost unit.

 

[gnsteam]

More work on the firewall tonight. I installed the gas pedal assembly. With the BC Broncos EFI throttle cable kit.

Before I can cut the throttle pull cable to length. How far off the upright floor, should the gas pedal be?

And here are some pictures of the cable connection. And cable routing in the engine bay. I am going to make a bracket. To pull the cable away from the spark plug wires.

 

[DirtDonk]

How high you put the pedal will depend at least in part on what kind of floor cover you’re gonna have.
Are you gonna have carpet and thick insulation? Floor mats? Minimal insulation? Nothing?
That would weigh heavy in the deciding factor I would think.

 

[gnsteam]

How high you put the pedal will depend at least in part on what kind of floor cover you’re gonna have.
Are you gonna have carpet and thick insulation? Floor mats? Minimal insulation? Nothing?
That would weigh heavy in the deciding factor I would think.

Yes there will be carpet and carpet backing material as well.

 

[.94 OR]

I think the "down" position is more critical.
At WOT I think you would want something to stop the movement and not just ending the travel of the cable.
That might be what dictatest the "up" position.

 

[gnsteam]

I think the "down" position is more critical.
At WOT I think you would want something to stop the movement and not just ending the travel of the cable.
That might be what dictatest the "up" position.

Very good point, thanks.

 

[DirtDonk]

But that comes with a caveat.
Definitely take a sample of the materials tou’re going to have on the floor and lay them under the pedal.
Push the pedal all the way and verify that the throttles are wide open.
The caveat is then, how high does the pedal come up to retract? There are many scenarios with Ford Efi where the pedal is far too high in order to get the full travel.
If you then put the pedal where it’s comfortable for your foot, ankle, knee, and hip, then it won’t open the throttle blade all the way.

You might have to mimic the bell crank set up that changes the ratio. Sort of a variable pulley setup.
I think it was Viperwolf1 basically taking a wheel/roller, creating an eccentric, so that the throttle moves slowly at first and then accelerates as you push it past halfway.
This was not primarily for full travel achievement, as much as it was to reduce the instantaneous (over exuberant) lurching during tip-in.