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Old 09/14/15, 09:47 AM   #1
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
Joined: Apr 15
Posts: 1,212
Duffy's 77 Build Thread- Restomod, daily, re-uncut

Hello All, I have been working on getting my build thread started.

Here is how the 77 started. A 5' away paint job done over abuse and neglect and mostly just issues from sitting in Arizona for so many years, luckily its very very rust free.

A little on the purchase. I bought the bronco site unseen (I know, not bright and I know better) I have been looking for a 76-77 for around 2 years and everyone that pops up sells almost instantly. My main goal was to find one that wasn't terrible with rust that ran and drove that I could enjoy as I slowly worked on it. When I found one that fit, I shut my brain off and jumped right in! The guy (Javier, nobody should ever buy from him) knew tons about broncos and really put my mind to ease. Running and driving rig with no rust and a rebuilt motor and new paint for 9K. Sounded like exactly what I wanted! I wired the money, setup shipping to have it moved and that's when the issues started to come up. Couldn't find the title etc... Then finally no texts or phone call returns after about the 3rd day, which I came to learn was about the time the bank wouldn't help me get the money back.

Lucky for me I have an Iphone and 2 of the 30+ pictures and videos he sent me were taken from an iphone and the pictures had the locations services turned on (gps tagging of the picture with location and time). When I clicked on the picture info I learned that the bronco was 5 hours away in a different town and a different part of the state. So at this point I get the police involved and I know I am getting scammed. Since I have his exact address I sent the local police to his house, they confirmed it was in the garage and then waited for someone to come home, which was his wife. About 5 hours later I get a nasty phone call from Javier, which was yelling and such. He claimed to the police that he gave a fake address so I wouldn't know where he lives and that I couldn't steal his identity. Yep somehow that worked! The detective said he figured he had been scamming people for a while with the same bronco, but I had no proof of the scam, and the bill of sale sold me the bronco, so at this point I had to take possession of the rig. Here it is.
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Old 09/14/15, 10:10 AM   #2
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
Joined: Apr 15
Posts: 1,212
Here is a list of what I have done, I will keep it updated.

1977 Bronco - Arizona original, very little rust
All black powder coating is Cardinal Bk08- Semi Gloss black
Every single nut or bolt is new (expect internals of engine, tranny, transfercase and drivelines) stainless or grade 8 zinc
Full 1990 Mustang 5.0 HO Conversion 82K original miles
All stock seam sealer removed, all rust removed and areas were chemically treated with ospho.
Professionally Motor Rebuilt (honed, rings, bearings and new seals) and paint and powder coated- All bolts stainless, New water pump and fan blade,*
EGR delete and AC pump delete, Billet alternator bracket, 130 amp alternator (90 amp at idle)
Silicone racing hoses throughout engine, including vacuum and water lines
K&N Filter with aluminum cold air intake- Powder coated
Racing aluminum radiator and aluminum shroud by ron Davis
D20 Transfer case rebuilt professionally, stripped and painted
New Bumpers- Hanson rear and protofab front, with custom hidden winch bumper- powder coated, brushed stainless C clamps
Custom Tire carrier by Protofab- Powder coated with stainless hardware, custom license plate holder and Led Lighting recessed
Marine Stereo- Wetsounds and clarion deck, 4-6.5" speakers and 4 channel class D amp, JL audio 8" subwoofer, Wetsounds wetwire used throughout.
DuffTuff interior aluminum door panels with custom upholstery
DuffTuff rear interior panels, aluminum with custom upholstery and speaker holes
New high pressure fuel pump and transfer fuel pump from aux to main tank.*
Stainless sending units for both gas tanks, both are poly and cleaned and painted. All stainless hardware and powdercoated
Gas tanks skid plates and straps powder coated
Ididit, Powder coated black steering wheel, 77 with hazards and column shift and turn signals, with custom cnc powder coated steering wheel
Custom wild horses lower steering shaft with dual universal joints
Dash- Deleted lights, speaker, ash tray, all stainless bolts and screws
Tuffy Glove box
Full family roll cage- Powder coated, seat belt attachments on cage
Toms Seats, Bases powder coated, new high end padding- custom high grade vinyl and custom grey, all seats are heated, both upper and lower
Center Console- Powder coated, USB plug stereo and usb power + heated seat dials. 20LB gas shock assist
New passenger rocker- original stamping.
Compustar Alarm and remote start
DuffTuff Hood gas shock kit- powder coated and stainlesss hardware
Front Disk brakes New- Wild horses
Optima Marine Battery- camburg stainless battery tray custom for optima
Painless 5.0 EFI wiring kit- split loomed
Painless wiring kit- original plugs re-installed for extra time and cost. Weave loomed and weatherpack connections for non stock componenets
Newport Engineering wiper motor - low profile, added dome light and interior light switches
Wiper arms powder coated from 1988 cherokee cut down 1-3/8 for 14" wipers 14-2
1977 Heavy Duty Rear End professionally rebuilt- 31 spline, trutrac 4.11 posi, narrowed 2", moved shock mounts, ruffstuff perches, stainless brake lines, media blasted and powder coated.
Front End, Professionally rebuilt, media blasted, powder coated New premium warn hubs New 4.11 gearing, stainless brake lines, Aluminum diff cover. Raybestos Professional Grade Suspension Ball Joint
NicksTrix custom steering, powder coated and professionally welded 1.35x.188 dom with gm 1 ton TRE by ruff stuff. Ruffstuff's the cure installed
Tom Woods 1310XB. 33" Rear and 27" Front. Polished and clear coated with dust boots. 2" Dom steel.
2.5" suspension lift, all new suspension parts and bushings, wild horses 3.5" front springs - Toms Leaf Springs - 2.5", ULTRA-FLEX, 11-pk, stripped and painted with flexible semi gloss epoxy
1" body lift, Poly bushing style, zinc grade 8 bolts
Ruff Stuff perches, rear axel moved back 1", also .5" lift rear.*15 degree pinion angle
Stainless brake lines throughout, stainless brake hoses to the brakes, with emergency brake
New heater core- aluminum, heater motor (bigger and faster) powder coated metal and stainless bolts and screws
Power steering box sand blasted, engine paint applied, grade 8-zinc mounting bolts and all stainless bolts outside
New front fenders- Full stainless install bolts
New Battery supports
New core support
New Inner fenders front and wheel wells- Stainless bolts
New Rear fenders- Uncut- Professionally grafted 77 gas doors
Brake pedal and gas pedal powder coated and stainless hardware with new billet aluminum pads
Emergency brake, powder coated and new hardware stainless and billet pedal
Hard fuel lines, clear coated, all Russell -6 connections and stainless braided gas lines
New Hood
Stainless tailgate handle- powder coated frame
New tail gate- Stainless bolts and screws, professionally deleted stock license plate holder and holes
New door rubber throughout and all new wing window parts. All stainless screws and hardware
New driver, passenger and deck floor pans
New seat belts throughout- 3 point front and rear.
Lokar Shift linkage
New wiper fluid tank and pump by toms
Full stainless headers- coated, stainless 2-1 exhaust, BC Broncos, Stainless hardware, 100% purge tig welded
New Led lighting throughout- Rigid dome light and door actived interior lighting.
New lighting buckets and lenses throughout, with stainless bolts and screws
New Samuri sun visors, single point attachment, custom vinyl to match interior
New window and door gaskets throughout.*
Rebuilt door internals, sand blasted and por 15 top coated inside of door. Billet cranks and arm rests, All internals were chemical dipped and all rust removed, Stainless bolts and clear coated
Brushed stainless vent windows, fully rebuilt, new gaskets and pivots.
New Wild horses Brake booster- Wilwood master cylinder
Power door locks, tied into the remote
New Hood striker (powder coated- zinc plated toms latch)
New silent bumpers for the tail gate- Wildhores*
New Dash Pad- Toms with custom stainless knobs
JB- Dual T stick shifter, stainless with billet shift knobs
Nicks Trix Door billet door cups and steering column bezel
Dakota Digital Gauge cluster
Gas filler necks chemically stripped and painted with new door bumpers
USSHIFT controller
4r70w out of a awd mercury 1996. Stock with 88k miles on it. Stock converter, Shift kit, new filter, painted aluminum grey
Advanced adapters with clocking ring installed to mate 4R70W to Dana 20
Professionally cut and welded transmission cross member to fit the Advanced adapter transfer case mount. Custom frame mount Powder coated and stainless bolts
Cable system for silent tailgate- Wild horses
Stainless door striking posts
Powder coated headlight parts- All stainless hardware
Powder coated tailgate strikers and all hardware
Door Latches- Zinc plated new from dynacorp
Stainless steel lenses kit- whole bronco
Billet Tail lights and marker lights- Powder coated Bk08
Billet door lock knob
Stainless windshield frame to roll cage connectors, 100% stainless
Powder coated 4r70w pan*
Stainless lift off hinges
Transfer case skid guard punched and dimpled and powdercoated
Stainless exhaust BC Broncos- custom stainless polished sanitary exhaust tip
Broncohut fiberglass headliner professionally covered in 100% nylon felt "Smoke" color
Stainless Magnaflow exhaust, lifetime warranty 2 into 1
Stainless coil locks front, front coil brackets powder coated, stainless bolts
Adjustable tracking bar 76-77 Toms Bronco Parts- media blasted and powder coated to match
Heater intake, powder coated metal, new stainless rivets, painted semi gloss black
Fox 2.0 Racing shocks, Front- 985-24-084 Rear - 980-24-645
Lokar Stainless -locking dipstick 5.0
Lokar Stainless- Billet transmission dipstick
Marine Grade Electrical Stainless Steel Cushion Clamps used on all wiring harness
Factor 55 Fairlead and thimble
Smittybuilt 9500 synthetic winch
Totron Rear facing Flood LED 1.5k Lumens Each
Rigid Industries SR-Q2 Front Facing Flood light LED, 3k Lumens Each
19mm Billet switches for OD, Mode and Fog Lights
Brushed Billet Aluminum rear view mirror

Hellwig Street sway bar, front- 100% new powder coated black. All zinc nuts and bolts grade 8
Drop Pitman arm, powder coated
Drake Billet Dash Bezels, Duff Billet knobs and custom billet power port plug

5- 285/70-17 BFG KO 10 Ply
5- Yuma black Rocks 17x8

Media blasted powder coated frame BK08
Media blasted all steering and suspension parts coated BK08

Last edited by duffymahoney; 08/18/16 at 09:48 AM..
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Old 09/14/15, 10:27 AM   #3
ep67bro
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EasternShore, MD
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Sorry you had such a bad time with the purchase. But you are lucky to have such a rust free truck to start with. I wish I could get my hands on one that rust free!

67, 289, NP-435, 3.5 lift,1"BL, 35s,custom bumpers, work always in progress. Wifes 73, 302, c4, 2,5" lift 33s driver,
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Old 09/14/15, 10:29 AM   #4
sprdv1
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Guess you better call the Whaaaambulance

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Quote:
Originally Posted by duffymahoney View Post

Lucky for me I have an Iphone and 2 of the 30+ pictures and videos he sent me were taken from an iphone and the pictures had the locations services turned on (gps tagging of the picture with location and time). When I clicked on the picture info I learned that the bronco was 5 hours away in a different town and a different part of the state. So at this point I get the police involved and I know I am getting scammed. Since I have his exact address I sent the local police to his house, they confirmed it was in the garage and then waited for someone to come home, which was his wife. About 5 hours later I get a nasty phone call from Javier, which was yelling and such. He claimed to the police that he gave a fake address so I wouldn't know where he lives and that I couldn't steal his identity. Yep somehow that worked! The detective said he figured he had been scamming people for a while with the same bronco, but I had no proof of the scam, and the bill of sale sold me the bronco, so at this point I had to take possession of the rig. Here it is.
Love it when a bitch like that gets their due. Congrats man, Hope it gives you lots of enjoyment

Nice rig

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Old 09/14/15, 11:39 AM   #5
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
Joined: Apr 15
Posts: 1,212
When I had the shipping company pick it up, he called and told me the bronco wasn't nice and barely ran onto his trailer. When I got it home, it was a rust free rig for the most part, but anything rubber, plastic turned to dust when you touched it. I decided it was going to be a frame off restomod project at this point.

Radiator had dirt in it, duct tape over wiring and then painted black to look clean, paint over everything. Basically my worst nightmare.




Yeah, I wonder how long he has been doing this to people. I kind of felt like I am saving people from dealing with him.

I decided on a EFI high end restomod build. Since everything was toast.

I have a 16 year old kid doing the body work, him and his dad are doing it together.

I found a 88 mustang H.0. motor that I had mostly rebuilt by a friend. New rings, bearings, honed cylinder walls, valve seats and just fully gone through. It had 70k original miles. I powder coated all the pans, valve covers, intakes etc.. Then all silicone race hoses and vaccum hoses. I deleted the egr and spent hours and hours cleaning everything! EGR motors are dirty! I then had my buddy that owns a monster truck building company redo my c4 and D20. They are fully built with race internals and such. I then did twin sticks from wild horses. Turned out sweet!
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Old 09/14/15, 11:56 AM   #6
broncobsession
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Freaking love that story! Bill of sale burned him. Looks very nice.

Always looking for the next project.
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Old 09/14/15, 12:45 PM   #7
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
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Every nut, bolt, screw and washer is going back stainless. I found kits for the engine and tranny online, the rest I am sourcing from the web or locally. I'm happy, but I didn't want to spend this kind of money right away!
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Old 09/14/15, 12:54 PM   #8
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

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Here is the dash, I went powder coated grey. I used JB weld as a sort of bondo to fill holes, smooth out dents etc.. I am going full marine audio in it. This is a high end clarion deck that is water proof. I want to be able to run the top off without worrying about the audio or the rest of the rig in a storm. Classy gauges rebuilt the speedo, I installed a tiny Rpm gauge by autometer and went all new switches and bezels along with a tuffy glove box.
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Old 09/14/15, 01:49 PM   #9
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
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Here is the frame. Media blasted down to bare metal, then por15 top coat over. The previous owner who I hate, decided he should undercoat the axles and frame over dirt and grease. It was so much fun cleaning up!
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Old 09/14/15, 03:07 PM   #10
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
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Here are my axles, both are fully rebuilt (the rear end was toast! It had mud in it!) by my friends monster truck company Spinney Bent Co. I went 31 spline in the rear, along with new 4.11 gears front and back and Eaton posi rear. Rear disk conversion from wild horses. Then new perches from RuffStuff. I will be moving my rear axle back 1". Now off to get stainless bolts and paint.
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Last edited by duffymahoney; 09/14/15 at 06:06 PM..
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Old 09/14/15, 05:57 PM   #11
broncoitis
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Sucks that it was such a hassle but you busted a Jerk that had it coming so good for you. Truck looks nice and you are off to a good start getting it back in shape. What is the target date to get it back on the road? Keep the pics coming!

Rob 1970 Bronco: Rebuilt 302, EFI, Exp Serp, Vintage Air, Cust Console, Corbeau Seats, etc...
Build: Springtime or Bust!!!
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Old 09/14/15, 06:09 PM   #12
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
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Posts: 1,212
Here is my steering column, all new wiring, new internals and bearings, along with powder coat. I am sticking with non tilt for the moment and see how I like it.
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Build Thread: Updated list of what I have done is on page one-
http://classicbroncos.com/forums/sho...d.php?t=259028
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Old 09/14/15, 06:12 PM   #13
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
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Here is the doors, they had zero rust inside! It did have about an inch of dust though. I sand blasted everything then did por15 top coat inside to make sure it will never rust. I fully rebuilt the window and the door internals with new gaskets, bushings etc.. Just waiting on paint.
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Last edited by duffymahoney; 10/25/15 at 08:33 AM..

Build Thread: Updated list of what I have done is on page one-
http://classicbroncos.com/forums/sho...d.php?t=259028
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Old 09/14/15, 06:21 PM   #14
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
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I'm going pretty high end on the stereo build. I am using wetsounds, which is the top of the line marine stereo gear. I was going to build the sub into the rear panel, but it became too difficult. I will have 2 6.5" in the door (previous owner cut) and 2 in the passenger area. They will get 150rms each pair and the sub will get 300rms.

I started off by buying new panels for the rear, but they are sadly stapled to cardboard. So I removed the vinyl, I then bought the broncohut fiberglass panels, then traced the cardboard shape on the fiberglass and re-cut them to match, then glued the vinyl back onto the fiberglass, tedious but it turned out great. I used stainless nuts and bolts to secure the speaker in, I also added studs for mounting my amp hidden and also hookup for the subwoofer. I added push things so that the panel will snap in and no screws will be visible. Once the panel is in and the roll cage is in, the whole setup will be very hard to remove or steal. I will also bolt the front speakers in, so they can't be just unscrewed.

check out www.wetsounds.com I have them in my boat and I have never heard a speaker personally that sounds better.
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Build Thread: Updated list of what I have done is on page one-
http://classicbroncos.com/forums/sho...d.php?t=259028
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Old 09/14/15, 07:00 PM   #15
duffymahoney
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1977 Re-Uncut, 5.0, Someday daily driver

Sandpoint Idaho
Joined: Apr 15
Posts: 1,212
Here is the sub box, fully rhino lined and siliconed to keep water out. Wetsounds marine subwoofer.
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Build Thread: Updated list of what I have done is on page one-
http://classicbroncos.com/forums/sho...d.php?t=259028
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