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My little mule Pe'pe

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broncomatt

broncomatt

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Joined
Dec 27, 2005
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284
more tear down

More tear down, Really rusty. Pulled all the coolers and radiator out. Cage will need to be blasted.
 

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broncomatt

broncomatt

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From concept to prototype, back to concept. Now for the final production.

So I have removed all the parts for the prototype, now its a concept again.
Some small changes, WH rear shock hoop instead of shocks threw the floor.
A BC gas tank instead of my own fuel cell. Stock dash and heater box.
Stay tuned as I go back to the build process.
:cool:
 

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broncomatt

broncomatt

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progress

Not done much but got some progress. Cage is screwed down to mark mounting position. Drilled holes and made cage tie ins with bushings to isolate vibration. I also moved the glove box door over and patched the dash holes. Welded in the axle truss and will put the shock mounts on next.
Hope to paint the engine bay soon and will be making the rock sliders. I also need to rework the engine cage and shock mounts. More to come.;D
 

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broncomatt

broncomatt

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more progress

Some progress again, finished all the cage tie ins. The cage now sandwiches the body and then ties into the frame with rubber isolation bushing I got from summit. Very much like a track bar or leaf spring bushing. All 8 points of the cage are tied into bushings that
then go down to the frame. The engine cage mounts directly to the frame so it can be used for shock mounts. Total of 10 points of cage tie ins.
The spare tire assembly is also installed, it swings out from the inside to allow me access to the inside but not have to have the
tire on the outside of the body. All my supplies fit nicely on the inside and I have an old gas can I plan to turn into a tool box.
Next step is to rebuild the front axle Powerloc clutch kit and reseal the rear end. Soon to be onto the body work and bed liner. Of
course first I have to pull the cage back out and paint it.
 

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broncomatt

broncomatt

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Dec 27, 2005
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284
back at it again

It has been several months but I'm back on this project again.
Fabricated new nerf bars with rock skis. These are all built out of roll cage tubing.
Welded in the shock mounts, cut the rest of the radiator support and fit in the dual trans coolers on the pass side and the oil and ps coolers on the drivers side. The fans go in front since there pushers. The fans are from a Nissan titan, I have several.
Next up is to drill and mount the gas tank, drill the front wheel well's for the shocks to pass threw. Then the cage's can come out to be painted. While that's being done I will finish all the body work and put in the bed liner. More to come...
 

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broncomatt

broncomatt

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Installed the gas tank, welded up the last of the holes from the spare tire rack, fixed all the rust holes in the windshield frame, stripped the inner fenders and finished the mods to the radiator support. Pulled the engine cage back out to strip and paint it. Put new axle bearings/seals on the rear shafts. Put rust treatment on the inner fenders, windshield frame, rear quarter patches. More to come....
 
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broncomatt

broncomatt

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Well I have made some more progress, not all of it good. I am going to use the soft upper doors that were on the roadster so I stripped my old doors, cut the rest of the frame off and welded a plate over the OE slot. The next step would be to drill and weld the tube in to accept the upper frames. I decided to mount the door to be sure the frame is exactly where I want it. This is when I found out the true shape of the tub. The door was off on the bottom more than can be achieved by normal adjustment. I installed the other door to be sure of my suspicions. Then I mounted the fenders and hood and grill. I went back to the photos of the tub when I first got the truck. The roadster's tub (ok the whole truck) had been dragged on the drivers side and the front clip was hit hard on the passenger side. So much so the fenders and grill were junk and I had to beat the quarters into some shape to skim coat them. The tub is twisted on both rear quarters and the front end is shifted to the drivers side. So to get the doors in line I'm going to put some relief cuts in the C pillars and pull till I get the numbers I'm looking for. Then I will pull the front end over to set the front end. I was hoping to be farther along with the body work but I'm glad I caught this before I wasted too much time on other aspects of the body prep. The good news is with some sand blasting the doors can be patched up, I found one spot in the tailgate that will need a patch. The grill is in better shape than I thought and with some hammer and dolly work it came into shape quick. Just need to skim coat and start sanding.
The other step I'm getting ready for is to put the rear fender flares on. I'm going to do things different (what a surprise huh!), I have been looking at the 3M panel adhesive. It is often used to put quarter panels and non structural body parts on cars for years. I'm going to try putting the flares on with that, not rivets. I will use a few machine bolts to hold the flares in place and secure till the epoxy cures. Then fill those holes in. Stay tuned....
 

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broncomatt

broncomatt

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Ok after loosing some time to a trip up north for easter, then coming back with bronchitis and a few other distractions I am finally back on the body work.
The soft top door mods are done, tailgate was patched and is mostly done. The hood is getting a new scoop, which meant welding up the old scoops mounting holes.
The last big part was mounting the fender flares. In the photos you see some screws and clamps holding them on. Those can all come off now! I used panel epoxie to put them on. It worked great and now I just need to fill in the screw holes and rivet dimples.
Now I'm going to be doing a lot of sanding to get it ready for primer and paint (which I already have).
 

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broncomatt

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stage one

After countless hours sanding, spot puttying and sand and fill primer. I shot the coat of sealer. I used a blue sealer to work with the paint. I need to go back and touch up the hood and tailgate but then I will try and shoot the base and clear coat next weekend.
 

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broncomatt

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After one failed attempt its finally painted. 3 coats of intense blue pearl and 3 coats of clear. Next is bed liner.
 

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broncomatt

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more progress

Now that paint is done it was on to bed liner and paint the cage. The dash is also painted and most holes are cut in for the gauges. Should have the cage in by the end of the week.
 

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broncomatt

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Got lots done in the last week, welded the nerf bars to the frame. Got most of the cage all painted in. Will be done by the end of the week.
Resealed the engine, put a new dampener on too. Other than a few seals the rest of the powertrain should be in by the end of next weekend. Then its on to the wiring.
 

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broncosbybart

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Looking good Matt!! Keep up the hard work. Where you are at can be very tedious at times.
 
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broncomatt

broncomatt

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made some headway

Made a bit progress. built brackets that mounted oil and ps coolers together. Made mounts for those coolers with a fan mounted. Ran oil hoses, mounted temp sending unit and remote oil filter. Did the same for the two tranny coolers and fan. Plus an external filter for the trany and another temp sensor. Mounted a washer pump, I still plan to try and clean it better or may try some paint. The radiator mounts are next along with the ps pump and hoses and alternator.
Most of the gauges are in but as you can see by the piles of parts to sort threw I still have much to put together.
 

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broncomatt

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down to the smalls

On to the small stuff. Fuel lines are run, headers are on, all coolers and fans are mounted. Once the brake lines and gauges are in its onto the wiring harness.
 

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broncomatt

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So nearly one year from being done and I am happy with how everything works. Hit lots of deep sand and a few surprise mud holes. Had to use 4wd twice to get out. Now it needs a bath;D
 

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