1984 Ford Bronco Project
- Thread starter Dakota Houligans
- Start date
What a really cool and involved build! You get kind of used to seeing a lot of parts that get bought and bolted on here.
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Sent from my SM-G950U using OB Talk mobile app
Thanks. I think I have a tool and tinkering/building stuff addiction. It just seems like I can usually find something close to what I want but just not quite. So I end up figuring out how to build what I want myself. That and why pay $1200 plus for a bumper when I have a welder and plasma cutter already (I did talk myself into getting a tubing bender for the bumper and other projects). If I include the price of the bender in the cost of my winch bumper it's about the same as It would cost to buy one. And now I have the ability to make more things. Also I have a little girl and some nephews that enjoy building things. It's fun to have a 5 year old daughter that has a welding helmet and her own rifle and knows how to use both!
I should probably get around to posting up the bumper pictures and info soon too.
I should probably get around to posting up the bumper pictures and info soon too.
Nice work on that Bronc! I had almost forgotten i had one once upon a time!
Sent from my SM-G955U using OB Talk mobile app
Sent from my SM-G955U using OB Talk mobile app
As someone who is a fabricator, I can definitely understand that. Its cool taking my little girl out and she can point out things that either I made or that came from my work even if I hadn't shown her the piece before hand
Sent from my SM-G950U using OB Talk mobile app
Finally build this bumper this fall. I've had a warn 16.5ti winch sitting under my work bench for too many years. Finally convinced myself to buy a tubing bender for some of the projects we have in mind. Started by making as much room as I could to push the winch and bumper as tight to the body as I could.
View attachment 45939
I had to cut the middle out of the lower trim. Also the center support and to be modified a bit to get the location I wanted.
Then I some 1/2 plate I had and made the bumper brakets. The center is a 2x6 1/4. I cut the center out of the back to weld a warn universal winch mount flush to the front.
View attachment 45940 added the mounting braketsView attachment 45941 View attachment 45942
I liked the fit and everything was fitting where I wanted it. I did remove the triangle part and got some premade recovery points. I finished welding it up and added some bracing in the corners. closed of the 2x6 to the winch mount and added some triangulationView attachment 45946
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So now it was time to fire up the bender and make the outer ends of the bumper. Upper bars located where I wanted them.
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And welded on the bench.
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Added a third bar to each end just below the recovery points. In case you wanted to know getting decent fitment at the end where all 3 came together was interesting but I eventually got it.
View attachment 45953 both the upper and lower tubes are welded to the recovery point to help strengthen it.
And another test fit on the Bronco.
View attachment 45954
Now I just had to decide where to mount my lights and if I wanted any grill or light protection. I was also debating on adding a front receiver hitch as well.
View attachment 45939
I had to cut the middle out of the lower trim. Also the center support and to be modified a bit to get the location I wanted.
Then I some 1/2 plate I had and made the bumper brakets. The center is a 2x6 1/4. I cut the center out of the back to weld a warn universal winch mount flush to the front.
View attachment 45940 added the mounting braketsView attachment 45941 View attachment 45942
I liked the fit and everything was fitting where I wanted it. I did remove the triangle part and got some premade recovery points. I finished welding it up and added some bracing in the corners. closed of the 2x6 to the winch mount and added some triangulationView attachment 45946
View attachment 45948
View attachment 45949
So now it was time to fire up the bender and make the outer ends of the bumper. Upper bars located where I wanted them.
View attachment 45950
And welded on the bench.
View attachment 45952
Added a third bar to each end just below the recovery points. In case you wanted to know getting decent fitment at the end where all 3 came together was interesting but I eventually got it.
View attachment 45953 both the upper and lower tubes are welded to the recovery point to help strengthen it.
And another test fit on the Bronco.
View attachment 45954
Now I just had to decide where to mount my lights and if I wanted any grill or light protection. I was also debating on adding a front receiver hitch as well.
After playing with several ideas I decided to do about a half height grill protection.
View attachment 45956
I also added the front receiver hitch since it does come in handy now and then. I cut it off an old one I had and welded ti to the bottom with some added reinforcement.
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Then final grinding, sanding and cleaning for paint.
Backside.
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Front side with the paint still wet.
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Paint dried. I used a valspar industrial paint in a low gloss black.
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On the Bronco with the winch installed.
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Lights and grill all back on.
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And from the side. I managed to keep it pretty tight to the front even.
View attachment 45966
We have used it several times and it has proven plenty strong.
View attachment 45956
I also added the front receiver hitch since it does come in handy now and then. I cut it off an old one I had and welded ti to the bottom with some added reinforcement.
View attachment 45957
View attachment 45958
Then final grinding, sanding and cleaning for paint.
Backside.
View attachment 45959
Front side with the paint still wet.
View attachment 45960
Paint dried. I used a valspar industrial paint in a low gloss black.
View attachment 45961 View attachment 45962
On the Bronco with the winch installed.
View attachment 45963 View attachment 45964
Lights and grill all back on.
View attachment 45965
And from the side. I managed to keep it pretty tight to the front even.
View attachment 45966
We have used it several times and it has proven plenty strong.
Nice work on all of the custom stuff. I'm sure that serpentine belt and Saginaw power steering pump are working wonders for you.
Thanks, it has been fun building and figure stuff out. Yes sir that serpentine belt has been great no more slipping belts and voltage drops from water, mud, and snow. Nice quiet and smooth steering now.
For sure. I'm swapping in a Saginaw pump into my '96 right now. Excited to get rid of the factory whine.
Member III
Thanks, I like how it turned out. Kind of a mix of ideas that fit the shape of the Bronco. Most of what I found for sale is just too big and bulky.
Winter was hard on the bronco. Poor thing has rust in all the wrong places. The B pillars are rusting out along with most of the rear quarter. So we figured it might be time to pick up one with less rust and start again. At least I have all good mechanical to put in one with a better body. I've had one sitting here waiting for me since spring. And a plan has started.
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I'd been looking around at good condition bronco's since last winter. A friend of mine found this one sitting around no longer running. The price was right and after sitting in my driveway waiting for me to decide what I wanted to do with it for a while. The work is beginning. We are going to combine the 2 and see what we can come up with.
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The inside.
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The wife and kids decided it was time to start taking the interior apart.
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Every one was helping.
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She likes helping build things. Especially her adventure mobile.
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Then it was into the garage to remove the rest of the interior and the windshield.
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Then it was time to patch a few spots in the front floor.
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I fanged the edges and used panel bond on this due to the difficulty in sealing the underside of the repair.
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Now time to move to some more complicated repairs due to the angle and curves.
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I cut the piece then bent the flange and used a stretcher to make the curve. Not perfect but it will do.
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Then I welded and panel bonded the top piece in.
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And did the same on the other side. Just a smaller piece to repair.
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After some pin hole touch ups it was done up front. Now on to the wheel wells.
View attachment 65450
The inside.
View attachment 65451
The wife and kids decided it was time to start taking the interior apart.
View attachment 65452
Every one was helping.
View attachment 65453
View attachment 65454
She likes helping build things. Especially her adventure mobile.
View attachment 65455
Then it was into the garage to remove the rest of the interior and the windshield.
View attachment 65456
View attachment 65457
View attachment 65458
Then it was time to patch a few spots in the front floor.
View attachment 65459
I fanged the edges and used panel bond on this due to the difficulty in sealing the underside of the repair.
View attachment 65460
Now time to move to some more complicated repairs due to the angle and curves.
View attachment 65463
I cut the piece then bent the flange and used a stretcher to make the curve. Not perfect but it will do.
View attachment 65469
View attachment 65470
Then I welded and panel bonded the top piece in.
View attachment 65471
And did the same on the other side. Just a smaller piece to repair.
View attachment 65473
View attachment 65474
After some pin hole touch ups it was done up front. Now on to the wheel wells.
Some of the rust that we decided not to fix on the old one.
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After some inspection of the b pillars I decided that the amount of time it would take to replace 2 rear quarter panels, both rockers, and hand make the b pillars on both sides behind the door. And a lot of the floor behind the front seats. That the massive amount of time it would take wouldn't be worth it. Not when I have 2 kids that want to play and go explore. So we decided to partially start over with a better vehicle to start with.
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After some inspection of the b pillars I decided that the amount of time it would take to replace 2 rear quarter panels, both rockers, and hand make the b pillars on both sides behind the door. And a lot of the floor behind the front seats. That the massive amount of time it would take wouldn't be worth it. Not when I have 2 kids that want to play and go explore. So we decided to partially start over with a better vehicle to start with.
Since it was all apart and I needed to do some repairs on the inner wheel wells I figured I'd make a little more room for tires or suspension travel. So I marked some cut lines.
View attachment 65575
Started cutting out the inner portion.
View attachment 65576
After checking with the rear seat I figured I can go to that body seem on the floor on both sides with out having to find different rear seats or get this one narrowed.View attachment 65577
It's not a huge amount of extra room but it will help with tire size and travel.View attachment 65578
Inner trimmed up and tacked in place.
View attachment 65579
Worked out better than I figured it would. Now to remove some more rusty parts and start filling the gap.
View attachment 65580
First few patches made and tacked in place.
View attachment 65581
View attachment 65582
Decided after this side that I would try to make it in one piece on the other side. Sure am glad the wife talked me into getting a plasma cutter!
View attachment 65583
The front was a little harder to do actually due to all the curves.
View attachment 65584
All welded in and mostly cleaned up.
View attachment 65585
After getting this side done I am going to attempt to make the patch and expansion all one piece so there is less welding and grinding. And a little less of the Frankenstein look.
View attachment 65575
Started cutting out the inner portion.
View attachment 65576
After checking with the rear seat I figured I can go to that body seem on the floor on both sides with out having to find different rear seats or get this one narrowed.View attachment 65577
It's not a huge amount of extra room but it will help with tire size and travel.View attachment 65578
Inner trimmed up and tacked in place.
View attachment 65579
Worked out better than I figured it would. Now to remove some more rusty parts and start filling the gap.
View attachment 65580
First few patches made and tacked in place.
View attachment 65581
View attachment 65582
Decided after this side that I would try to make it in one piece on the other side. Sure am glad the wife talked me into getting a plasma cutter!
View attachment 65583
The front was a little harder to do actually due to all the curves.
View attachment 65584
All welded in and mostly cleaned up.
View attachment 65585
After getting this side done I am going to attempt to make the patch and expansion all one piece so there is less welding and grinding. And a little less of the Frankenstein look.
Time for the drivers side and the attempt to do it in one piece.View attachment 65588
Plenty of room now.View attachment 65589
Cut lines marked on the inner fender.
View attachment 65590
Inner tacked in place and starting to remove the rest of the damaged area.
View attachment 65591
Area to be patched all cut out and prepped.
View attachment 65592
I tapped some paper sheets together to make a big enough template of the area and then traced it onto some sheet metal and cut it out with the plasma cutter and a little fine tuning with the grinder then some bending and tacking.
View attachment 65593
Yup, that worked much nicer. It was a little trickier to shape and fit but quicker and looks better this way. Not that anyone will see it once its all back together.
View attachment 65594
Almost all welded up.
View attachment 65595
Now I just need to burn up a few flap wheels. dig out some primer and seem sealer. But I'll probably fist the last little bit on the rear of the floor before I spray the primer.
Plenty of room now.View attachment 65589
Cut lines marked on the inner fender.
View attachment 65590
Inner tacked in place and starting to remove the rest of the damaged area.
View attachment 65591
Area to be patched all cut out and prepped.
View attachment 65592
I tapped some paper sheets together to make a big enough template of the area and then traced it onto some sheet metal and cut it out with the plasma cutter and a little fine tuning with the grinder then some bending and tacking.
View attachment 65593
Yup, that worked much nicer. It was a little trickier to shape and fit but quicker and looks better this way. Not that anyone will see it once its all back together.
View attachment 65594
Almost all welded up.
View attachment 65595
Now I just need to burn up a few flap wheels. dig out some primer and seem sealer. But I'll probably fist the last little bit on the rear of the floor before I spray the primer.
Time for a little patch work on the rear by the tailgate. So I removed the tailgate, rear bumper, and fuel tank.
View attachment 68146
The spots to replace.
View attachment 68148
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I cut out the rust and ended up patching a small piece below it as well.
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I cut out 2 replacement pieces and bent the one to match.
View attachment 68151
Then welded and panel bonded them in place.
View attachment 68152
View attachment 68153
While that was drying I wend and did the other side as well. It turned out ok. Ended up with a pretty good fit. With the help of a hammer of course.
View attachment 68154
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Finally the floor repairs and changes are done. It took longer than expected since I still have a few kids to pick on too.
View attachment 68146
The spots to replace.
View attachment 68148
View attachment 68149
I cut out the rust and ended up patching a small piece below it as well.
View attachment 68150
I cut out 2 replacement pieces and bent the one to match.
View attachment 68151
Then welded and panel bonded them in place.
View attachment 68152
View attachment 68153
While that was drying I wend and did the other side as well. It turned out ok. Ended up with a pretty good fit. With the help of a hammer of course.
View attachment 68154
View attachment 68155
View attachment 68156
Finally the floor repairs and changes are done. It took longer than expected since I still have a few kids to pick on too.
Forgot I had some spots on the lower part I fixed to. Had to cut open the side to get at all of it.
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This corner all back together.
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This corner all back together.
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Now it's time for sanding and cleaning it all up for primer.
View attachment 68160
I used 120 grit on an electric sander and then washed it with soap and water using a scotch brite pad to get any spots I may have missed and rinsed it off.
View attachment 68161
After letting it dry overnight. I wiped it all down with a pre-cleaner and then it was time for some epoxy primer.
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2 coats of ppg epoxy primer on and dry. Next I put some SEM 2 part seam sealer on all the seams.
I've heard some good things about Lizardskin from some friends that build hotrods so we decided to put some on this one.
View attachment 68166
First 2 coats of their sound deadened material on the front.
View attachment 68167
Next I need to put 2 coats of their thermal insulation down. Then when that is dry I can spray some on the rear of the bronco.
View attachment 68160
I used 120 grit on an electric sander and then washed it with soap and water using a scotch brite pad to get any spots I may have missed and rinsed it off.
View attachment 68161
After letting it dry overnight. I wiped it all down with a pre-cleaner and then it was time for some epoxy primer.
View attachment 68162
View attachment 68163
View attachment 68164
View attachment 68165
2 coats of ppg epoxy primer on and dry. Next I put some SEM 2 part seam sealer on all the seams.
I've heard some good things about Lizardskin from some friends that build hotrods so we decided to put some on this one.
View attachment 68166
First 2 coats of their sound deadened material on the front.
View attachment 68167
Next I need to put 2 coats of their thermal insulation down. Then when that is dry I can spray some on the rear of the bronco.
