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"Rust Never Sleeps" World Build Thread

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Alpacket

Alpacket

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Oct 31, 2012
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241
World's Most Interesting Winch ...

To finally get my top off, I bought a 440 lb hoist from Harbor Freight and installed it up in the ceiling of my garage. These things are designed to mount to 2" square tubing. But since I didn't have access to my garage ceiling from above (that's my bedroom floor) and wanted as much clearance as possible, I mounted it using 1" galvanized pipe spanning two joists and attached to each using 1" pipe floor mounts and lag bolts. And for irony, I covered it with one of those medallions for ceiling fans. Turned out pretty clean and works great.
 
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Crawdad

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Feb 16, 2011
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I have one of those winches, got it from HF. I have it hanging in the attic to pick up stuff I don't use during the winter that otherwise clutters my garage. I had my stock wheels PC'ed too. I regret having two coats put on, last coat being a clear to dull the silver down a bit. It's a bear to balance them, but it all worked out. Keep up the good work!
 
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Alpacket

Alpacket

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Oct 31, 2012
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Punched the tar baby

Sorry it's been a while since my last post. Life and other interests get in the way. But I have been working on the Bronco, too. I had an inkling that something was off with the body, so a few months ago I pulled the engine and got into it. When I did, I found a bunch of crappy repair by the PO. Stuff like galvanized sheet metal over rust holes attached with self tapping screws. And lots of it. So I decided to get to the bottom of things. Well, you can see in the pictures, that resulted in substantial demo. Right now, driver's side fender, inner fender, kick panel, inner rocker, outer rocker and now the seat platform are all toast. I'll try and post as I weld stuff back in. So far, my minimal bracing has kept me from loosing any angles or distances, ... I think.
 
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Alpacket

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Weird stuff ...

When I pulled the motor, I found a bunch of metal stuff in front of the flywheel. Looks like mostly some type of retainer.
 
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Alpacket

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Patch

Also welded in a patch at the driver's side firewall. Turned out okay, I think.
 
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Alpacket

Alpacket

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By the way, the plan is for Med. Green Glow.
 
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Alpacket

Alpacket

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Halfway there ...

Another past-due update. The inner skirts, front fenders, kick panels, inner and outer rocker panels, seat platform, and lower quarters are all in. And the doors fit! At least to my standards. The picture of the glass below was my celebratory bourbon.

The Dynacorn stuff was alright IMO, although it did take substantial persuasion of the hammer variety to get some of it to fit. To my surprise, the front passenger fender was the worst due to some really inattentive spot welds. The driver's quarter was the best. It went on without a hitch.

Every time I hit this truck, something falls off. So now I've determined the bed, wheel wells, both fuel filler neck extensions, and both upper quarters need to be replaced due to rust. Looks like I unintentionally purchased not so much a Bronco but more a pattern to build one. I hope to be substantially done with panel replacement by July 4, 2015, so I can paint by the end of that summer.

By the way, I've decided - with this much work - I deserve a 351w. So if anyone in the Kansas City area is looking for an all original '76 302 with boat anchors and a steady unwillingness to hold oil pressure, have I got a deal for you.

Also, picked up these neat little wheel dollies from Northern Tool and highly recommend them.
 
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Alpacket

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Lift

Oh, and I forgot to mention, I found some slightly used WH 2 1/2" coil springs on eBay, so I threw those on and WH's 1 1/2" lift blocks on the back for fun. I think its cool at least.
 
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Alpacket

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Not dead ...

Thought I would throw up a few photos just so you would know I'm not dead and my thread wouldn't get archived. Inner fenders are in, and the bed and wheel wells are about done. Fuel filler extensions are probably next. Won't make my July 4 goal for all metal done, but that's okay.
 

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Alpacket

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Off by .25 of an inch ... Thoughts?

I don't know if I got the truck this way or I fell down a bit on the job somewhere, but the rear door posts each lean in .25 of an inch. So at the bottom of the posts, near the floor, they measure 56 inches apart, and at the top, they measure 55.5. I'm getting a bit OCD about it. Tried to take some pictures but you can't really see it. Try to fix it or leave it alone?
 

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Alpacket

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Some more photos ...
 

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Bferrari

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Mar 6, 2013
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How do your doors line up? If they are off then I would try spreading it with a jack or port a power. I would base a lot on the door fit regarding your fix.
 
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Alpacket

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Thanks for the encouragement. I'll take all I can get. These projects are a bit brutal. The doors do okay. I know we complain about them, but there's really a lot of adjustability built in there. I'll post some pictures of the door fit tonight so you can see it. Thanks, again.
 

surfer-b

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I cant really tell from the picks but it looks like the doors line up good as far as the top or bottom not stickn out. I do see a few Broncos where the bottom of the door will be stickn out past the sheet metal which I think really looks bad and the top of the post needs pulled in. If the doors close as should and all the gaps look good I would prob leave it as is
 
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Alpacket

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More door pics ...

Here are some more pics of the doors. I think the line up pretty well. Ignore the gap at the back of the driver's side door. I'll fix that later with shims. Anyway, I feel like its okay and I'll just move on. Good enough for government work, as my father would say.
 

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Alpacket

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With the echoes of the amplifiers ringing in your head ...

Okay, its not Neil Young, but it fits.
 
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broncoitis

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Nice job so far. You have gotten alot done and should be proud of where you have gotten it so far. Keep it up. ;D
 
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Alpacket

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Thanks, Broncoitis. Restoring a frame today I found for $100. I'll post pictures soon.
 
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