The Duck Build.

[englewoodcowboy]

Well with SC just a few short days away, Im afraid my bronco wont make it this year. I did manage to get some more done today, the bed is just a few scraps left. Basically the only part of the rear bed area that will be original will be the inner fenders, tailgate posts and support brackets. Everything else is or will be BSN.

 

[Bferrari]

Your rig is looking great! At the pace your going, you'll be ready for paint next week!

 

[englewoodcowboy]

I wish! I still have the pass door bottom to replace, both door skins and replace the pass side panel on the hard top as well... not to mention all of the pieces I need to cut out a fab patches for on the rear inner fenders. Im hoping to have it in primer by mid May which means when the epoxy primer goes on, all of the welding on the body is done. Then I need to give the frame some attention, it has no issues other than cosmetic and I want to add a frame brace at the steering box.

 

[Bferrari]

Well keep up the good work! I am just digging into mine, in process of getting it off the frame onto the rotisserie. I've been keeping up with your build thread and it's got me pumped to get going on mine!

 

[englewoodcowboy]

Got a little more done. I need to roll it outside and sandblast the inner fender area and start fabbing up patch pieces in a few places then it's time to install the new bed.

 

[englewoodcowboy]

Knowing tomorrow was my day to prep my truck, load my junk and get ready to roll to SC, I figured today would be the last day till Monday that I get to work on my bronco.... and work I did. I sand blasted all the rust off, Ospho and ground as well as hammered and dollied the edges back into shape. Then it was mock up time. The whole bed is mocked into place but I still need to do a little trimming on the floor panel to get in finished, then when I get home I will pull it apart, grind the e-coat off were I need it gone, copper coat it fab and replace 5 patches and fit it all back together, once that is done then the task of burning it in begins again.

 

[jmeyer1971]

Why do you prefer clecos over self tappers. I don't see a difference but you clearly have a better grasp on this than I do.

 

[englewoodcowboy]

The biggest thing I like about the clekos is they only make an 1/8" hole and it is flat. Self tappers or tech screws warp the metal at the hole if you have to pull it apart and they make a larger hole to fill when you are fitting and have to move things a lot like door posts. I do use tech screws when I am limited on clekos or if I need to pull metal together like when I move the front of the bed pan under the seat pan, I will use tech screws since I do not have clamps big or long enough to secure things. The best thing with the clekos is mocking things up as well. I can set a cleko, pull it and shift things slightly and then just drill through the same visible hole to make a change. With tech screws you have to move the whole thing and drill 2 new holes again. Both work and have their place, once you try clekos, I do not know of anyone who said they do not love them.

 

[jmeyer1971]

Makes sense I will give them a try on my floor pans....thanks

 

[englewoodcowboy]

floor pans you would probably use a combination of both. The clekos do not have the clamping power the tech screws do. Where the really shine is in the body panels and multi panel fit. Good luck and have fun.

 

[Bferrari]

The biggest thing I like about the clekos is they only make an 1/8" hole and it is flat. Self tappers or tech screws warp the metal at the hole if you have to pull it apart and they make a larger hole to fill when you are fitting and have to move things a lot like door posts. I do use tech screws when I am limited on clekos or if I need to pull metal together like when I move the front of the bed pan under the seat pan, I will use tech screws since I do not have clamps big or long enough to secure things. The best thing with the clekos is mocking things up as well. I can set a cleko, pull it and shift things slightly and then just drill through the same visible hole to make a change. With tech screws you have to move the whole thing and drill 2 new holes again. Both work and have their place, once you try clekos, I do not know of anyone who said they do not love them.

I'm going to buy a cleko kit to do the same thing you've been doing. How many do you find yourself using at any given time? I want to make sure I order enough. Are you only using the 1/8"?

 

[englewoodcowboy]

I'm going to buy a cleko kit to do the same thing you've been doing. How many do you find yourself using at any given time? I want to make sure I order enough. Are you only using the 1/8"?

Sorry it took so long to get back to your Q. I was at SC. As for your Q, look on Amazon, I got my best deal there with Cleko Brand clekos and bought 50 of them and the knock off pliers. Having to fit the entire bed I could have used another dozen but I also have tech screws. For everything else, 50 has been plenty. Def. go with the 1/8" and do yourself a favor and buy a bag of 1/8" Screw Machine drill bits from MSC or Grainger or another machinist supply. They are way better than what I have gotten at Tractor Supply or Harbor Freight.

 

[englewoodcowboy]

Back in the shop for the first time since SC and I finished fitting the bed, marked everything that needed to be drilled for welding etc and have been prepping it for the permanent install. Also cut out the last of the rot and have to fab the patch panels. Only a few pics today, more will come tomorrow as I move forward.

 

[englewoodcowboy]

Well my Bronco was pushed to the side today for another more pressing project. On my return from SC I lost my turbo and had to limp it home. I ordered a new rebuild kit for it and it arrived last night so I decided to see just what had happened all the while suspecting a seized bearing. Well this is the second time I have rebuilt the turbo (did it last winter) and the instructions in the kit I had never mentioned lock tight so I did not use any and 4 bolts that hold the compressor housing to the bearing housing had loosened and wedged against the compressor wheel topping the turbo from working, I was very lucky to not have any damage other than the expense of a new rebuild kit. Since I had to remove the turbo and disconnect the exhaust, I should also mention I won the 50% off Flowmaster Coupon at SC, I decided to use my discount to purchase a new exhaust for my tow rig. The turbo is fixed waiting to be reinstalled and the stock exhaust is on the ground. My bronco is in the corner for some time out till I get my truck back out of my shop, then its time to make some more headway.

 

[englewoodcowboy]

Almost done with the sideline project of my truck... My new exhaust is due in today and if all goes well I will be welding on the Bronco tomorrow.

I think this is definitely a sign of my A/C compressor about to go

New A/C compressor and drier

and I replaced these leaky guys while I had the turbo out

When all of this is done my tow rig/daily driver should be good to go for a while I hope... at east till my bronco is done. I am getting bummed seeing my bronco funds getting used on other things besides my bronco...

 

[englewoodcowboy]

I finally got my shop back. The green machine lives again!

 

[NicksTrix]

so how's it run and sound? how come no flapper on the end of the tip?

 

[broncoitis]

Truck is looking good! Now get that thing back in the shop where it is getting worked on and not shoved in the corner. ;D

 

[englewoodcowboy]

It sounds great and the power has gone way up. It turned out the the two leaking pipes have been leaking for a long time and they were not allowing the turbo to run at max efficiency. It's like driving a new beast. The A/C is cold enough to hang meat if I wanted too. Lol

Today I will get some metal cut and welded in and depending on how much time I get in the shop, maybe get the bed installed for good. Then it leaves me with the quarters to hang and I am very close to having the tub complete! Then I have the doors and top to do....

 

[mjramacher]

the bronco is looking good very nice job on the metal work its keeping me motivated on my build.