1984 Ford Bronco Project

[Dakota Houligans]

On to the passenger side door. This one had less rust and no dents so I have a much smaller area to fix.



Cleaned up and ready for some new metal. Unfortunately I forgot to take any photos of it after.





I took the piece I removed and used it as the template for the patch. I cut the patch a half inch taller to give some area to glue.



Inside primed and waiting for the patch panel.

 

[Dakota Houligans]

Here is the passenger door glued back together.



All sanded down with 80 grit.





2 coats of epoxy primer.





I managed to git some filler work and smoothing done on the drivers door.



I forgot to take some pictures of the door before I sprayed epoxy over it to seal it up. But I did take one of after the epoxy.





some filler on the passenger door and lots of sanding then it's filler primer time... and more sanding.

 

[Sparksalot]

Fantastic progress.

 

[M Rose]

You’re entering the home stretch now @Dakota Houligans

 

[Dakota Houligans]

Fantastic progress.

Thanks, It's been a lot of work.

 

[Dakota Houligans]

You’re entering the home stretch now @Dakota Houligans

Yes sir, getting closer to putting the fun parts in.

 

[Dakota Houligans]

And the sanding and coats of filler primer have continued.









Finally have it all smooth and straight. So I can scratch and dent it latter...





Tomorrow I should be able to lay a coat or 2 of epoxy over it to seal it up.

 

[Dakota Houligans]

Started on fitting the upper shock mounts this afternoon as well. I had to trim some of the heat shield out of the way for clearance.



I had to drill out the original holes for some 1/2 inch bolts.









After some looking I decided to just trim the heat shield back all the way to the cross member. Fits pretty good. A little clean up and it will be ready to install.

 

[Lanlubber In Remembrance]

You lost me on this mod. I'm not sure where the heat shield is in the picture and I dont understand what you are attempting to do with the shock mount. I guess I just don't know the suspension geometry on the bronco. What is the round cross bar with the brackets, what is it's function ?
Not you fault, it's mine.

 

[Dakota Houligans]

You lost me on this mod. I'm not sure where the heat shield is in the picture and I dont understand what you are attempting to do with the shock mount. I guess I just don't know the suspension geometry on the bronco. What is the round cross bar with the brackets, what is it's function ?
Not you fault, it's mine.

Sorry I'm getting tired. I had already cut out the heat shield in those pictures. It was in the way of the bar and would have hit the shock as it cycled. The bar and brackets are the new upper shock mounts for the rear to use longer remote reservoir shocks. The 3 bolts you can see in the last picture on the frame are the original shock mount location. so it raises it a fair bit.

 

[Lanlubber In Remembrance]

Sorry I'm getting tired. I had already cut out the heat shield in those pictures. It was in the way of the bar and would have hit the shock as it cycled. The bar and brackets are the new upper shock mounts for the rear to use longer remote reservoir shocks. The 3 bolts you can see in the last picture on the frame are the original shock mount location. so it raises it a fair bit.

Thanks, I was on the wrong end of the bronco. Thought I was looking at front suspension parts. Duaaaaaaa

 

[M Rose]

Started on fitting the upper shock mounts this afternoon as well. I had to trim some of the heat shield out of the way for clearance.

View attachment 169990

I had to drill out the original holes for some 1/2 inch bolts.

View attachment 169991

View attachment 169994

View attachment 169995

View attachment 169996

After some looking I decided to just trim the heat shield back all the way to the cross member. Fits pretty good. A little clean up and it will be ready to install.

View attachment 169997

I was going to ask if you did the fuel pump access mod... but I see it’s done... I think I’m going to do that in the springtime.
Are you going back with the standard 19 gallon tank, or the JBG 35 gallon extended tank?

BTW your Bronco(s) are my inspiration... I really wish I could take the time right now to strip mine all the way down like yours and build it up.

 

[Dakota Houligans]

Started on fitting the upper shock mounts this afternoon as well. I had to trim some of the heat shield out of the way for clearance.

View attachment 169990

I had to drill out the original holes for some 1/2 inch bolts.

View attachment 169991

View attachment 169994

View attachment 169995

View attachment 169996

After some looking I decided to just trim the heat shield back all the way to the cross member. Fits pretty good. A little clean up and it will be ready to install.

View attachment 169997

I was going to ask if you did the fuel pump access mod... but I see it’s done... I think I’m going to do that in the springtime.
Are you going back with the standard 19 gallon tank, or the JBG 35 gallon extended tank?

BTW your Bronco(s) are my inspiration... I really wish I could take the time right now to strip mine all the way down like yours and build it up.

I have a 30 gallon tank for it. As low as it hangs I'm not sure I'd want an extra 5 gallons. Access and serviceability are very useful things.

Thanks, good to know I inspired you instead of just my empty wallet!

 

[Dakota Houligans]

Sorry I'm getting tired. I had already cut out the heat shield in those pictures. It was in the way of the bar and would have hit the shock as it cycled. The bar and brackets are the new upper shock mounts for the rear to use longer remote reservoir shocks. The 3 bolts you can see in the last picture on the frame are the original shock mount location. so it raises it a fair bit.

Thanks, I was on the wrong end of the bronco. Thought I was looking at front suspension parts. Duaaaaaaa

It happens. I was having one of those nights last night so I understand.

 

[Dakota Houligans]

I got the doors sealed up finally.





Rear upper shock mount installed for the final time.



Also got the rear hangers lowered and installed.



Then I enlisted a little help with putting the bushings in the shackles. He was very excited to help and get to use a hammer.



Shackles test fitted with the leaf springs.



The original springs compared to the new ones. They are a modified version of the deaver q80's. About 2 inches of lift but a lot more travel.





Now I think I'll start on the front suspension since it is still nice enough to have the garage door open.

 

[Dakota Houligans]

Pulled the front axle and radius arms off.



First time I've had a ball joint stick this bad. it was easier to take it out of the knuckle than separate the stud.



Some work with a cut off wheel and air hammer and the coil buckets and ttb pivot mounts are off.



And after a few more parts are removed. now to clean everything up for some welding.



After some cleanup and welding of cross members It will soon be time for some funner parts.

 

[Lanlubber In Remembrance]

Pulled the front axle and radius arms off.

View attachment 172052

First time I've had a ball joint stick this bad. it was easier to take it out of the knuckle than separate the stud.

View attachment 172053

Some work with a cut off wheel and air hammer and the coil buckets and ttb pivot mounts are off.

View attachment 172054

And after a few more parts are removed. now to clean everything up for some welding.

View attachment 172055

After some cleanup and welding of cross members It will soon be time for some funner parts.

View attachment 172056

Clean up ! So dang time consuming but so important in my opinion. Based on what I'm seeing it looks like you will not be able to ever remove the body again when you finish welding your shock bracket bar to the frame and roll bar cage on both sides. Is that correct ? I cant tell from the pictures if your tying the cage to the frame in front of the firewall.

 

[Dakota Houligans]

Clean up ! So dang time consuming but so important in my opinion. Based on what I'm seeing it looks like you will not be able to ever remove the body again when you finish welding your shock bracket bar to the frame and roll bar cage on both sides. Is that correct ? I cant tell from the pictures if your tying the cage to the frame in front of the firewall.

Still debating on that. I've considered using some bolt together unions so it could be separated if needed.

 

[M Rose]

Still debating on that. I've considered using some bolt together unions so it could be separated if needed.

I would. Just in case the body ever needs to come back off.. besides it will allow the body to flex better with the frame.

 

[Dakota Houligans]

A little more done on the front suspension. I finished welding up the shock hoops.





I put the axle beams in place and put the coil-overs in place. It is fitting pretty nicely.



I still have to let the nitrogen out and remove a spring so I can make sure everything clears before I weld the lower mounts on to the axle beams.



The new radius arms a just a slight step up.





Completely compressed.



And fully extended. both sides are check and now to weld the lower mounts on the axle beams.



Comparison of the original size front shocks to the new coil-overs.



My ocd kicked in again and I had to cap the ends of the lower tubes on the upper shock mounts. Not much practical need but I looks a lot more finished this way.



Now, I just need some more clean up and prep to add a few more finishing touches to the front suspension.