Sam P. 71 Bronco Tub rebuild.

[sp71eb]

How did you attach your tail light housings? Did you plug weld the housing to rear bedside/post and Pro Spot the edge where it fits to the tailgate? I have thought about using 3M 8115 to hold it on. I have used a lot of 8115 putting my tub together. Figured it would keep the moisture out very good. Very strong also. I have Dynacorn housings as well, with Tom's upper/lower bedsides and wheel tubs. thanks

The top bedside I drilled from the inside and plug welded to the taillamp pocket. the middle where you can access throught the taillamp hole I plug welded that section. The bottom where I had access I used the spot welder. and I also used the spot welder on the lip by the tailgate. I wouldn't use the adhesive on the whole thing. If you check on their website 3m doesn't recommend using only glue on things like tailgate post. If the glue gives loose on the ends from the repeated stress of the weight of the gate it will come loose. What I would do if you plan on using the glue is put one plug weld at each end of where you are gluing and glue the rest. Hope this makes sense.

 

[TPTFPS68]

Yes, it makes perfect sense. I was going to plug weld everywhere it meets the bedside and stitch weld the top to the post hole. then glue the area where it meets the tailgate. Using a Pro Spot to weld thru the glue in a couple spots is a great repair, but I don't have that luxury at home. thanks

 

[sp71eb]

A/C and heater box install

Well yesterday I planned on finishing up my efi wiring harness but RJM still hasn't shipped my order....So I decided to get my a/c and heater box mounted. The unit is from southern rods. The kit seems pretty nice and is way cheaper than the vintage air units. I can't say for how well it works yet. I was debating cutting the right side cowl and have now decided to cut it out so I can tuck the heater box higher up and behind the dash. After I got the cowl cut out I welded in a boxed chunk of 18gauge steel. As you can see in the pictures I gained about 2 or 3 inches by cutting the cowl. I mounted my heater box and then moved on to mounting the computer and figured out where to run the plug through the firewall. I have been taking a lot of time trying to tidy up my wiring and mesh the universal body harness and efi harness together and keep them removable and serviceable.

 

[sp71eb]

Dash refresh

Went into work today for a few hours and I decided it was time to get my dash squared away. I wanted to move the glove box over, delete the hacked radio hole, delete the speaker grill, delete the ashtray, delete the fuel switch, and remove the heater control holes so I can re drill them for my southern rods a/c and heat controls. I also got rid of the dash pad holes and any other added holes on the dash. I tig welded most of the dash until I ran out of argon. After welding up the dash I got it mocked up for my new heat controls and vents.

 

[sp71eb]

Finally Back At It!

Well I finally got back to working on the Bronco. Two weeks ago we took a trip to the Ozarks and last weekend I had my wife's 10 year school reunion%). Today I got back at it. I ordered up some aluminum pipe for my intake and a K&N filter. I also got a led light that put in one of the old bezels that I had laying around for my check engine light. I got the cluster, ignition switch, headlamp switch, and brake dummy light wired up. I then started wiring the passenger side wheel well area. I got the starter solenoid installed and wired up my alternator, horn, fan relay, and used some 2 gauge welding cable to wire up my starter. Hopefully tomorrow I will get all of my body harness wired up. Also I finally got a shipping confirmation from RJM after a month and will finally have all of the efi wiring stuff I need Monday!

 

[sp71eb]

Sunday I got some more work on the wiring completed. I had a rough night Saturday, we went and saw the 80's cover band Hairball and this guy drank too much black velvet so I got a late start Sunday. I got the rear section partially wired up. I used some weld on studs to run the wires. After I get everything ran I will cover the wires in convoluted tubing and clean everything up. I also finally received my order from RJM so I can finish up my EFI harness. (the taillight isn't lit up in the picture it is just the flash from my camera)

 

[TwoDalesDad]

I have to say up front....I made a call to the local police department just now. By the time you get there the whole place should be swarming with officers from these following departments....Homeland security, Local Sherriff, Service Officers FBI, Meter Maids, Auto Theft Task Force, and last but not least...The local Humain Society... Criminal behavior ..jn the first degree.......For making Us Watch as you take your sweet arse time .....I will have you know.....You have more room around your bronco......than my entire shop.....did it work?....All Rivht I Confess...The Work you have just completed Is incredible...please at leasy throw some band aid wrappers on the floor....something....it just looks to F#$% perfect..LOL....GREAT WORK!!!!!,

 

[sp71eb]

Today I got the left side of the engine compartment partially wired. I also started connecting my efi harness to the body harness. I put some resisters on the tab and tad solenoid connectors. I also made a coil bracket for the left fender well. Getting close to finishing up the wiring to the point of testing it and pulling it to put the convoluted tubing over it. Tomorrow I plan to cut my vent holes in the dash, install the ac and heat knobs in the dash, finishing up the front wiring, mounting my battery, and testing the wiring.

 

[Dieselnutz]

I make very few comments but I have to give credit where it is do! Very nice and quick work! I will be checking back and asking questions.

 

[sp71eb]

Today I got all of the wiring done except the headlights and a few miscellaneous things such as dome light and my cig lighter. I drilled the holes in my dash for the heater controls. I also fabricated a mount for my efi relays and inertia switch under the dash. I modified my rad support to give me about another 1/2 inch for my electric fan and then found that I need a different condenser than the one I have to fit in front of the radiator. I also made a template for my new front bumper that I am going to start making here in the next few weeks.

 

[sp71eb]

Well today I got a lot done and came home feeling pretty accomplished. I mounted my battery tray from ruffstuff in the factory location. I found that I could bolt under the battery where there are holes and use the holes in the radiator support mounts. I then put some tabs on the battery box to help hold it better. I then made a mount for the washer/radiator tank, I could have mounted it on the inner fender but I didn't like how the caps were slightly obstructed. After all of that I decided that I would make my chassis wiring harness modular. I have lots of weatherpac connectors so I split my harness into three sections. A main section, a headlight section, and a taillight/fuel tank section. This will make servicing and installing the harness easier. I got the headlamp section finished up and also removed the tail section out of the truck and have it ready for covering with convoluted tubing. After finishing up all of this wiring things should start moving along faster. This crap sure is time consuming.

 

[sp71eb]

Went ahead and installed my loomed headlight harness today. I also loomed the rear section harness. I finally got the holes cut in my dash for the vents and also installed a 12v plug so my wife can charge her phone. I also installed a switch for the rear fog lights that I plan to install on my rear bumper. I'm hoping to hook them up to the reverse light and also a switch on the dash. I am going to use white oval led trailer style lights in the rear bumper. If I have time tomorrow I would like to get the rest of my wiring pulled from the truck and wrapped.

 

[sp71eb]

Put in another day of work today. I installed the upper radiator hose that some have recommended on here for the champion radiator conversion and found that if I rotated it where it is parallel to the radiator then it would fit better, so I cut it in the center and added a joiner pipe to it. Its not as clean but gets the job done. I reinstalled the rear wiring harness so I can test it. I then loomed up my efi and interior wiring harnesses. I then re-installed all of the harnesses and tested them. Then removed them for the 100th time. At least now I should only have to install them one more time. I started running my a/c lines and heater lines. I'm nearly ready to pull the body from the frame and raptor the underside.

 

[Teal68]

I love checking out your build. I don't post too much, but I have to say you are doing great work and it's looking stellar! Looking forward to seeing more.

 

[stupidboy]

This build is making me want to break mine back out of hibernation and get going on it again!!! Great work!!

 

[Wyo4x4er]

Nice work man! I am not to far from you, just outside ames. Well usually, im overseas right now and this thread makes me want to work on mine so badly. You should bring her to the offroad show in Nevada, last year i had the only bronco there.

 

[sp71eb]

Nice work man! I am not to far from you, just outside ames. Well usually, im overseas right now and this thread makes me want to work on mine so badly. You should bring her to the offroad show in Nevada, last year i had the only bronco there.

I lived in Ames for 4 years and have a good friend from Nevada. I would love to bring it to Nevada this year and make it a 2 Bronco event. I have heard of a red EB running around the Cedar Rapids area lately, but I have yet to see it. Not many Broncos running around here in Iowa.

 

[sp71eb]

Today I had some free time and decided to powder coat some small parts that I had laying around. I coated the battery tray, upper radiator mounts, coil bracket, and the mount for my washer/coolant tank. I then started running my heater lines and am pondering mounting my ac drier in the outside of the right fender well. I ran my heater lines through the right inner fender to meet up to where my aftermarket heater core is. I started modifying my radiator support to use the condenser that I have for my a/c system. I didn't think it would fit and ordered a new condenser, the company I ordered it from screwed up the order and canceled it on me so I have been waiting the last week for nothing. So I am trying to makes lemonade from that situation. Had to do some serious trimming and am going to have to reinforce the lower section of the rad support.

 

[sp71eb]

Yesterday I spent about 5 hours making a square peg fit a round hole. I had to do some serious cutting and trimming to get the a/c condenser to fit. I now have it installed and looking good. I cut a lot of the lower rad support and had to reinforce it with some square tubing. I also notched the top where the #8 fitting is for clearance. I rubber mounted the condenser to the radiator support and then ran the ac lines. I then made a block off plate where the old heater intake was for my a/c and heater hoses to run through. I now have almost everything pulled from the tub and it is about ready to come off the frame.

 

[sp71eb]

No going back now. Its Cut!

Today I finished pulling everything from the tub to get it ready to take off the frame. And I'm sure I also pissed off some purist today. I cut the quarters. It was a weird feeling cutting two freshly replaced panels but I really like the way it looks now. The Bushwacker flares have a nice fit and help cover up my 33x12.50 tires.