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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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!
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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
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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.
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.
added the mounting brakets
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 triangulation
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.
And welded on the bench.
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.
both the upper and lower tubes are welded to the recovery point to help strengthen it.
And another test fit on the Bronco.
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.
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.
added the mounting brakets 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 triangulation
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.
And welded on the bench.
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.
both the upper and lower tubes are welded to the recovery point to help strengthen it.And another test fit on the Bronco.
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.
Attachments
After playing with several ideas I decided to do about a half height grill protection.
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.
Then final grinding, sanding and cleaning for paint.
Backside.
Front side with the paint still wet.
Paint dried. I used a valspar industrial paint in a low gloss black.
On the Bronco with the winch installed.
Lights and grill all back on.
And from the side. I managed to keep it pretty tight to the front even.
We have used it several times and it has proven plenty strong.
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.
Then final grinding, sanding and cleaning for paint.
Backside.
Front side with the paint still wet.
Paint dried. I used a valspar industrial paint in a low gloss black.
On the Bronco with the winch installed.
Lights and grill all back on.
And from the side. I managed to keep it pretty tight to the front even.
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.
The inside.
The wife and kids decided it was time to start taking the interior apart.
Every one was helping.
She likes helping build things. Especially her adventure mobile.
Then it was into the garage to remove the rest of the interior and the windshield.
Then it was time to patch a few spots in the front floor.
I fanged the edges and used panel bond on this due to the difficulty in sealing the underside of the repair.
Now time to move to some more complicated repairs due to the angle and curves.
I cut the piece then bent the flange and used a stretcher to make the curve. Not perfect but it will do.
Then I welded and panel bonded the top piece in.
And did the same on the other side. Just a smaller piece to repair.
After some pin hole touch ups it was done up front. Now on to the wheel wells.
The inside.
The wife and kids decided it was time to start taking the interior apart.
Every one was helping.
She likes helping build things. Especially her adventure mobile.
Then it was into the garage to remove the rest of the interior and the windshield.
Then it was time to patch a few spots in the front floor.
I fanged the edges and used panel bond on this due to the difficulty in sealing the underside of the repair.
Now time to move to some more complicated repairs due to the angle and curves.
I cut the piece then bent the flange and used a stretcher to make the curve. Not perfect but it will do.
Then I welded and panel bonded the top piece in.
And did the same on the other side. Just a smaller piece to repair.
After some pin hole touch ups it was done up front. Now on to the wheel wells.
Attachments
Some of the rust that we decided not to fix on the old one.
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.
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.
Started cutting out the inner portion.
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.
It's not a huge amount of extra room but it will help with tire size and travel.
Inner trimmed up and tacked in place.
Worked out better than I figured it would. Now to remove some more rusty parts and start filling the gap.
First few patches made and tacked in place.
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!
The front was a little harder to do actually due to all the curves.
All welded in and mostly cleaned up.
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.
Started cutting out the inner portion.
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.
It's not a huge amount of extra room but it will help with tire size and travel.
Inner trimmed up and tacked in place.
Worked out better than I figured it would. Now to remove some more rusty parts and start filling the gap.
First few patches made and tacked in place.
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!
The front was a little harder to do actually due to all the curves.
All welded in and mostly cleaned up.
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.
Plenty of room now.
Cut lines marked on the inner fender.
Inner tacked in place and starting to remove the rest of the damaged area.
Area to be patched all cut out and prepped.
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.
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.
Almost all welded up.
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.
Cut lines marked on the inner fender.
Inner tacked in place and starting to remove the rest of the damaged area.
Area to be patched all cut out and prepped.
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.
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.
Almost all welded up.
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.
The spots to replace.
I cut out the rust and ended up patching a small piece below it as well.
I cut out 2 replacement pieces and bent the one to match.
Then welded and panel bonded them in place.
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.
Finally the floor repairs and changes are done. It took longer than expected since I still have a few kids to pick on too.
The spots to replace.
I cut out the rust and ended up patching a small piece below it as well.
I cut out 2 replacement pieces and bent the one to match.
Then welded and panel bonded them in place.
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.
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.
This corner all back together.
This corner all back together.
Now it's time for sanding and cleaning it all up for primer.
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.
After letting it dry overnight. I wiped it all down with a pre-cleaner and then it was time for some epoxy primer.
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.
First 2 coats of their sound deadened material on the front.
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.
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.
After letting it dry overnight. I wiped it all down with a pre-cleaner and then it was time for some epoxy primer.
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.
First 2 coats of their sound deadened material on the front.
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.
