The Rebuild 4.0

[TAC71]

Its been over nine years since the last major overhaul and My Bronco is showing its age. Its my daily driver,weekend wheeler and gets driven on 4-5000 mile roadtrips. With the rockrash, damaged and worn parts a full rebuild is required.

Only a few major changes will be done since I am very happy with the way it performs. Most of what will be done is refinements, cleaning, rebuilding and repainting.

I drive 99% of the time with just a custom made bikini top and hardly ever use the custom made soft top. In 17 years its probably been on less than 3 months in total and its now falling apart. One of the major projects is to build a fiberglass modular roof. A three piece top that incorporates a bikini and full top together. The three sections of windows for the full top will be removable and store inside the rear full top section.
I will fab new bumpers and aluminum rad. The rear axle housing will get new tubes and a full rebuild.
The flares will get modified and much needed new paint will go on.

My wife even said "your truck is a mess, you need to fix it up".

So I started on it 4 weeks ago , here are a few progress pics

 

[RT]

I need a hardtop that'll fold back over the tailgate. Gotta have what little sun we get in my face as often as I can. Oh and a sunroof !

Will the front top fold back at all?
Damm Gary , if she thinks that's a mess she would shudder at what we travel in
Yours looks all luxo in comparison.

 

[lonesouth]

looking forward to the build

 

[BRONCOchild]

This is what makes EBs great vehicles. The versatility of converting it into something else or adding stuff onto it is endless.

I always thought, why don't companies have restorers make them a promotional vehicle. Not just to put their product on, (ie Rancho shocks or Bikini tops), but rather use it for all sorts of promotional tours. For example, I'd like to see an EB with the hardtop sides that open up and nothing but tools are laid out, like the MATCO tool trucks.

Just an idea.

 

[TAC71]

I need a hardtop that'll fold back over the tailgate. Gotta have what little sun we get in my face as often as I can. Oh and a sunroof !

Will the front top fold back at all?
Damm Gary , if she thinks that's a mess she would shudder at what we travel in
Yours looks all luxo in comparison.

The whole thing will be removable, but I generally leave the bikini top on all the time. No it will not fold back since I hardly use the full top anyway.
I see your in Surrey ...have I met you?

 

[RT]

Yup , seen you at the SOB's, 35th and 40th anniversaries and a couple car shows here while you were working booths for the shops you worked with.

You'll know my wreck when you see it
Was gonna say junk , but I just couldn't type that ,, Hah!!

Gotta get together on this side of the border sometime

 

[TAC71]

It would be cool to get a bunch of EB owners from the lower mainland together. Of coarse, my truck wont be ready for a while.

I'm in strip all the rest of the stuff off the frame mode. Gotta get it stripped so I can do some mods to the chassis. Then it all can go for sandblasting and powdercoating.......but I'm getting way ahead of myself.....

 

[TAC71]

Have most of the frame mods done. Just a few small details to finish there. Body mods are in bodywork mode.....did I mention I hate sanding bodywork. Hope to have the frame off to sandblast and powdercoat in 3-4 weeks.
I have had this fiberglass body for 25 years now....boy time flies...I could feel the rear floor getting soft. It has a laminated plywood core in the floor of the tub that has rotted away. Just a different kind of rust. Peeled out the old wood and will glass in some aluminum ribs.

 

[sprdv1]

The whole thing will be removable, but I generally leave the bikini top on all the time. No it will not fold back since I hardly use the full top anyway.
I see your in Surrey ...have I met you?

Looks great man, like what you did there.

 

[Prizefighter]

That windshield and wiper conversion is sweet.

 

[TAC71]

The sanding on the body is well on its way. All the major work on the outside of the body is done just need to sand it up to primer stage.

Did some fun work on the bumpers and sliders. Bent up a new upper tube for the front bumper that follows the grille mods and will give more protection for the fenders. Mounted the new Hella lights and the winch will still use the original removable saddle mount. Added some small extensions to the sliders for a little more side protection. The sliders are so well used there was virtually no powdercoat on the bottom of them. Rear bumper still needs to get done.

The new aluminum floor brace will also be a mount for the batteries which will mount in the rear floor.

 

[xcntrk]

Dude that front bumper looks great!

 

[TAC71]

Thanks for the compliments.
Gotta keep the progress going so I can get to some Bronco events in 2016.

 

[sprdv1]

Thanks for the compliments.
Gotta keep the progress going so I can get to some Bronco events in 2016.

Great plan. Wheel that thing and meet lots of great folks.

good luck bud

 

[TAC71]

got the primer sealer on tonight.......making progress

 

[broncokak]

Nice work! That's going to be some nice looking when you get it done.

 

[TAC71]

Finally the paint...just finished putting on the first colour. Hopefully tomorrow night I can do the second colour.

Also got the frame sitting on my trailer ready to go for blasting and powdercoat. Gotta love it when the big parts are just about ready for final assembly.

 

[TAC71]

Sprayed the blue on it tonight, not perfect, but pretty happy with the results.

Now I have to decide on a blacked out grille like I had or leave it blue.

What would be your choice ?

 

[tirewater]

Sprayed the blue on it tonight, not perfect, but pretty happy with the results.

Now I have to decide on a blacked out grille like I had or leave it blue.

What would be your choice ?

I like the grill blue. Or blue with silver grill section.

Up to you though.

 

[TAC71]

Got the frame, bumpers , wheels and stuff back from blasting and new coat of semi gloss powdercoat. Didn't cost nearly what I expected, what a relief.
Cleaned up the engine , transmission, dual T case and propane tanks. Now for the fun part .....put it all back together .....hopefully in time to make the AZ stampede. I have 6 weeks and a full time job that is getting in the way of my Bronco plans!