• Welcome to ClassicBroncos! - You are currently viewing the forums as a GUEST. To take advantage of all the site features, please take a moment to register. It's fast, simple and absolutely free. So please join our community today!
    If you have problems registering or can't log into your account, please contact Admin.

The Evergreen Bayou Project 2022

bayoubronco

Contributor
Newbie
Joined
Aug 1, 2019
Messages
37
Greeting CB!
This forun has been a valuable resource in getting me this far and I'm finally gettng around to returning the favor in sharing what I have (which is still more than what I know..lol) I'm sharing as much for input from the experts as well as introducing and offering insight from one more original survivor.

As the custodian of our family's 1976 Wagon, I'm taking on a Phase 1 of a restoration project. The goal is to get it functional while keeping it original. This entails getting it running, moving and stopping. I have a 6 month timeline which is dependent on the garage I'm borringing. My Uncle acquired it in 1978 and has had very little modification. I had it shipped to Seattle in Oct and am making some progress that I will update on this tread. I've also udated my garage for hopfully non-duplicate info.
(Added a few pic's)
 

Attachments

  • 20211007_110555 (2).jpg
    20211007_110555 (2).jpg
    205.9 KB · Views: 64
  • 20211025_132113.jpg
    20211025_132113.jpg
    154.7 KB · Views: 66
  • 20211026_141543.jpg
    20211026_141543.jpg
    193.2 KB · Views: 57
  • 20220118_173952.jpg
    20220118_173952.jpg
    210.2 KB · Views: 62
  • 20211008_091235.jpg
    20211008_091235.jpg
    213.7 KB · Views: 27
  • 20211008_092306.jpg
    20211008_092306.jpg
    191.7 KB · Views: 29
Last edited:

Howard2x4x4

Contributor
Bronco Guru
Joined
Apr 19, 2014
Messages
1,682
My, my, looks like a real solid survivor. Good luck and keep us posted. Howard in beautiful west Michigan
 

fordfan

Contributor
Bronco Guru
Joined
Sep 13, 2009
Messages
3,280
Congrats on you getting to be the caretaker for this '76. It looks great! They are only original once and it looks too nice to modify or restore. I think this Bronco made the Calendar competition also.... October 2022. Keep posting, because we like seeing progress!:)
 
OP
OP
bayoubronco

bayoubronco

Contributor
Newbie
Joined
Aug 1, 2019
Messages
37
October/November 2021 was about Electrical "gaps" primarily by the battery/starting components and under the steering wheel. I chose to fix existing issues and not do the full harness replacement. Now, there's over 50 splices which now allows for circuit testing, maybe not functional, yet. We did get ignition spark and sputter this month; which is obviously very exciting. Heater box is mostly painted and waiting for rebuild kit. Starter and Alternator bench tested. Oil Filter took longer to remove than the most other items. I think our frustration is evident on that one.
 

Attachments

  • 20211027_102219.jpg
    20211027_102219.jpg
    266 KB · Views: 39
  • 20211011_094116.jpg
    20211011_094116.jpg
    209.2 KB · Views: 40
  • 20211026_132100.jpg
    20211026_132100.jpg
    324.8 KB · Views: 39
  • 20211101_132919.jpg
    20211101_132919.jpg
    150.9 KB · Views: 41
OP
OP
bayoubronco

bayoubronco

Contributor
Newbie
Joined
Aug 1, 2019
Messages
37
The Power Steering leak from October 2021 has been a very frustrating endeavor. I drained reservoir, removed hoses, and the darn thing continued to leak. I finally ID'd the front housing area and it still took a month to get the thing off. The Pitman Arm Tool did not fit over the arm. I used loaner tools from big box store, and with the right one not fitting, the wrong ones not working, (breaking one in the process), I finally got the mgr appoval to grind down the tool itself to get it over the arm. (the pic shows the bend in the tool and that's stuck on the arm) Once the tool was seated propely, the "Beast" impact wrench popped it off like butter. It's amazing when you do things right way. Then, finding one O ring ended up being another month and a dead end...so, got the gearbox gasket kit and only used the front end cap rubber gasket and nose ring clamp. The rest of the gearbox is dry and smooth operating; so I'm lowering the prioirty on a full rebuild. (I can't find the current pic, so I'll edit later and add it)

It's now sitting in a tray, not leaking, waiting for install. (trying to keep access to the fuel pump while we focus on fuel system.)
 

Attachments

  • 20211007_153644.jpg
    20211007_153644.jpg
    198.2 KB · Views: 21
  • 20220103_163823.jpg
    20220103_163823.jpg
    161.6 KB · Views: 22
  • 20220112_140603.jpg
    20220112_140603.jpg
    152.8 KB · Views: 22
  • 20220109_113742.jpg
    20220109_113742.jpg
    139.4 KB · Views: 24
OP
OP
bayoubronco

bayoubronco

Contributor
Newbie
Joined
Aug 1, 2019
Messages
37
There’s a very interesting phenomena happening…the work hours are in 2-4 hour increments and seem to be creeping along; while the calendar days just keep clipping by. I can’t believe it’s been 6 months.

December progress was hampered by holidays and vacation (which was awesome). It did include testing the wire splicing job by connecting the battery and assessing the starting/lighting systems. One day in particular, we began continuity testing the starting components, solenoid, starter, coil, etc., and in different key ignition positions. I accidently moved the switch to start and cranked the engine; thus, our first Key/Ignition/Starter test passed! I had to scramble to re-plug everything back in and even got combustion. It was getting late and the idea of having spark next to a dangling Molotov cocktail bottle…was reason enough to stop, take the win on an unexpected milestone and regroup to include more of the fuel system.

We did get to some basic testing in with the lights and instrument cluster (thanks for all the posts on the importance of ground wires!) We found several that were not visibly impaired; but, checking the ground first saved a lot of time and good bulbs.
 
OP
OP
bayoubronco

bayoubronco

Contributor
Newbie
Joined
Aug 1, 2019
Messages
37
January was real progress and a big milestone. We had Spark and sputter in Dec and it was motivation to get the fuel system up to par. We installed a new carb, gas tank and Fuel Pump and cleaned up original fuel lines. I’m bypassing the gas tank at the moment; again, I just don’t want that much fuel introduced into the project. We got Key ignition and engine running thru the fuel pump and main fuel line to a red gas can in the rear.
The water pump/cooling system kicked on. (Currently bypassing Heater box.). Got up to 180, but now need to verify operating temp and if thermostat is stuck open. The PS box is finally reinstalled and I replaced a cracked hose. It’s now waiting for fluid, belt and a steering wheel to call complete. I’m still assessing, removing old (and ordering new) brake lines.
 

Attachments

  • 20220118_173949.jpg
    20220118_173949.jpg
    183.3 KB · Views: 25
  • 20220123_152451.jpg
    20220123_152451.jpg
    125.6 KB · Views: 27
  • 20220121_190135.jpg
    20220121_190135.jpg
    196.5 KB · Views: 27
  • 20220126_121523[1].jpg
    20220126_121523[1].jpg
    113 KB · Views: 14
Last edited:
OP
OP
bayoubronco

bayoubronco

Contributor
Newbie
Joined
Aug 1, 2019
Messages
37
After getting the basic “running” milestone completed in Jan 2022, the project priorities moved on to Stopping and Driving (Dash and Steering). I did a temp brake job in Aug 2021 using a new MC, bypassing the PV, plugging the small reservoir and tapping just the front brakes for transport. So, Feb 2022, it was time to go after the whole system. Removing the old, rusted parts was more time consuming than I expected; I think I have as many hours in removing as I do installing. With some left over galvanized lines; I took a shot at fabricating and got the front and rear brake lines loose fit. I bought new hoses and a PV, but waited on the MC to PV hoses.

We continued with Engine tuning and Installed new cap, rotor and wires, and working thru the carb tuning, PVC, EGR, etc vent ports. (Separate TS Post coming) It’s amazing how one loose plug can throw off the tuning process...oops. Using a cheap airbox as temp solution. Caught the new carb wingnut screw was sitting too high and would have punctured the hood, had I shut it too hard. That’s cut and smoothed. I did drag out the big blue un-balanced beast and test fit. I got the PS fluid filled and belt installed; couple burps and top-off and PS is working nice. Continued chasing electrical lighting splices under the steering wheel and fixing ground wires with lost contacts as pre-cursor to getting the dash back on.
 

Attachments

  • 20220227_144303.jpg
    20220227_144303.jpg
    171.5 KB · Views: 10
  • 20220305_162448.jpg
    20220305_162448.jpg
    174.4 KB · Views: 9
  • 20220227_155714.jpg
    20220227_155714.jpg
    177.1 KB · Views: 8
  • 20220227_155702.jpg
    20220227_155702.jpg
    155.8 KB · Views: 9
Last edited:
OP
OP
bayoubronco

bayoubronco

Contributor
Newbie
Joined
Aug 1, 2019
Messages
37
March 2022, the 6 month mark was a wake-up call on the need to put things back together and how many tasks are really needed before the Dash goes back on.

Yet, the Brakes became the saga of the month. It started easy enough with test fitting/bending the MC to PV lines. A little confidence from last month was quickly squelched; when, I was reminded that a Soft Steel Flaring will win out over brass (PV) ‘most’ of the time. I had to replace a brand-new PV for over tightening. I got cold feet and tried to order pre-fab’d hoses; but, due to backorders and waiting a few weeks, I ventured back to fabricating my own. I did get the whole Brake system loose fit and tightened enough for bleeding. Then, the Gopher game began: press pedal, look for leaks, find one, tighten, find a second, tighten, find one you just tightened leaking again. It felt like progress getting the bubbles and weak links figured out but we just could not get the pedal firm. We noticed low pressure while rear bleeding so we started loosening tube nuts I just tightened (so frustrating). Finally, figured out the MC (only 6 mo old) was not pushing enough thru the small reservoir. We replaced it, did more bleeding, Gopher chasing, adjusting the rear brakes. And with all of that, we are officially claiming the braking system working!

Tranny has a small leak and it finally stopped dripping out of the shifter lever, last month. We decided the better approach was to top it off and conduct the Driving/moving tests to find the gremlins. It only took 1.5qts and a lot of “Don’t over fill” slow pours; but it engages and moves forward and reverse!!! The Xfr case 4x4 seems to work, we have 4H N and 4L functioning. We are getting a weird 2H only moves with Locked front hub; like it’s a “front wheel drive” situation (Separate TS post coming!)

Dash is on and secured enough for driving! That required a multitude of tasks…like firewall insulation, heater box re-assemble and installed, e-brake and gas pedal re-installed. (e-brake loosened again for dash install), slipping the dash over the steering column AND shifter lever, (it actually does slide over) Dials and instruments re-connected, wire harness mostly secured, steering wheel re-attached.

Other loose ends…Differentials drained and replenished, undercarrage Zerk’s greased, Radiator flushed, driver door panel re-installed, gas tank secured.
 

Attachments

  • 20220317_113548.jpg
    20220317_113548.jpg
    229.3 KB · Views: 21
  • 20220317_134917.jpg
    20220317_134917.jpg
    190.8 KB · Views: 18
  • 20220322_133307.jpg
    20220322_133307.jpg
    173.6 KB · Views: 15
  • 20220324_165045.jpg
    20220324_165045.jpg
    201 KB · Views: 16
  • 20220325_114912.jpg
    20220325_114912.jpg
    153.9 KB · Views: 16
  • 20220329_130458.jpg
    20220329_130458.jpg
    231.8 KB · Views: 19
  • 20220403_142333.jpg
    20220403_142333.jpg
    272.7 KB · Views: 18
OP
OP
bayoubronco

bayoubronco

Contributor
Newbie
Joined
Aug 1, 2019
Messages
37
As of March 31st and at the 6th month mark, I have 243 hands-on hours (not including computer, parts ordering and research time) and just over $2K in parts and supplies invested. We have hit most of our main goals. The Engine starts nicely and comes up to temp, maintains 180 degrees; the Tranny and Power Steering are getting it around and the Power Brakes (and E-brake) are firm and doing the stopping. We have a lot still to do even just for 'road worthy' but we are making point turns in the driveway and finding the gremlins. We have some carb adjustments, a 2H FWD issue, and lots of securing loose components. We also have wheels, axles, suspension, and key rust areas, still to tackle and the borrowed space hopefully thru May.

This one picture may seem incomplete; but it represents the accomplishments of the project to date and my change in mindset from parts storage to a very real, functioning Survivor, showing it's character. ...even without the driver seat!!!
 

Attachments

  • 20220403_194758.jpg
    20220403_194758.jpg
    321.8 KB · Views: 15
Last edited:

sprdv1

Contributor
REBEL
Joined
Mar 8, 2007
Messages
79,142
As of March 31st and at the 6th month mark, I have 243 hands-on hours (not including computer, parts ordering and research time) and just over $2K in parts and supplies invested. We have hit most of our main goals. The Engine starts nicely and comes up to temp, maintains 180 degrees; the Tranny and Power Steering are getting it around and the Power Brakes (and E-brake) are firm and doing the stopping. We have a lot still to do even just for 'road worthy' but we are making point turns in the driveway and finding the gremlins. We have some carb adjustments, a 2H FWD issue, and lots of securing loose components. We also have wheels, axles, suspension, and key rust areas, still to tackle and the borrowed space hopefully thru May.

This one picture may seem incomplete; but it represents the accomplishments of the project to date and my change in mindset from parts storage to a very real, functioning Survivor, showing it's character. ...even without the driver seat!!!

Nice.. :) any accomplishment is better than none
 
Top