Project: 76, Orange Special Decor

[gnsteam]

Well it has been a few weeks after the sale of my steam locomotive project. I am now fully focused on the Bronco. I thought I would bring up my old list of upgrades, from post number 1 of this thread. And see how close it compares to my wants for the Bronco today.

Post #1
My plans for the 76.
Upgrade the Bronco to be more road worthy and comfortable for long trips, along with upgrades to improve it's off road capabilities for light to moderate trials. I want to be able to drive the Bronco anywhere from coast to coast, to attend as many Bronco related events as possible.

Here's a brief list of the future major upgrades, in order of priority.
Adjustable track bar. (Already purchased)
Wild Horses, 2.5" suspension lift kit with Bilsten shocks.
"Y" to "T" steering linkage upgrade.
New wheels and tires. Following the vendor mass buy, for 17" x 9" MHT Indy slots. http://classicbroncos.com/forums/sho...d.php?t=236592
And looking at LT315/70R/17 Goodyear Dura Tracs.
One inch body lift.
Body repair and repaint to original colors with new decor stripe, and color matched Bronco design fiberglass flairs. I'm also in the process of upgrading to the Sport trim level. I only need to install the grill trim and the Sport badges, which I already have. Sport interior upgrade will come later.
Plate bumpers, front with winch and rear, featuring tire carrier, and possibly fuel can and cooler racks.
Rocker protection.
Explorer EFI 5.0 engine and 4r70w tranny upgrade.
Twin sticks.
Vintage air AC.

I have to say the list is still pretty relevant. I haven't changed much from my intended usage, other than being more focused on Overlanding Exploration. So I'm still look for reliability, comfort and capable to drive anywhere any distance in all conditions. What has change on the list is my choice of components. Over the last few weeks I have been busy ordering and receiving parts for the upgrades. So here is what is on order or has already arrived.

James Duff
2.5" Duck Tuff suspension package
Long tube ceramic Headers and at a later date an exhaust system

Tom's Bronco Parts
Dana 44 rebuild kit with new chromoly axles, heavey duty u-joints, 4:56 gear set. and ball joints.
Ford 9" rebuild kit with new 31 spline axles and 4:56 gear set.
4R70W to Dana 20 adaptor and cross member
Twin Sticks for AOD transmission
23 gallon EFI tank with in tank pump and skid plate
3 core reverse outlet aluminum radiator
New plate style 6 point family cage

Wild Horses Motor Sports
Dana 44 ARB Locker
Ford 9" ARB Locker
ARB compressor
Saginaw dual return PS pump with serpentine pulley and bracket
130 amp 5.0 alternator
FlowKool water pump
Extreme Motor Mounts
Aluminum radiator shroud

Ruff Stuff
Dana 44 diff cover
Ford 9" pinion guard
Ford 9" spring perches for axle moved back 1"

The 96 explorer 5.0 will be off to the machine shop in a few weeks for a rebuild with a new Comp Cam K35-349-8
4R70W is on the waiting list at local rebuilder
And I have been in contact with Garry (EFI Guy) about the wiring harness and PCM re-flash.

Now to get started with the tear down. I'm going to pull the body off the frame. Blast rebuild and repaint the entire drive train with the parts listed above and more parts to come. The body on my 76 is very, very solid. So for now I'm only going to address the rust at the inner fenders clean it up keeping the original patina. Although I prefer a shiny paint job. I don't have the funds to go full out with a paint job. And I don't want this to turn into a multi year rebuild. I want this back on the road ASAP!

Sorry for the long winded post and thank you for following along on my journey. I'm sure I will be hitting you all up for help and advice. This will be my first attempt at a project like this.

Regards,

Fred

 

[gnsteam]

Friday I drove the Bronco over to a local muscle car restoration shop, to have them look over the Bronco for full rotisserie paint restoration. I will be doing the drive train. They came recommended by several very picky people I have a meet. The place is called, Muscle Car Concepts and Restoration.
www.musclecarconcepts.com
After an hour or so taking with the owner, I felt very comfortable placing my name on his wait list, for around December. After telling him that I was going to be taking the body off the frame soon. He even offered the spare frame that he has, complete with casters to put it on. They have built two Bronco in the past and is currently working on a 68. Turns out I know the person that owns the 68, and I already had his number in my phone. We meet a couple years ago at a local show. His daily driver is a 96. I will be giving him a call this week.

Today I pulled the Bronco into the center of the garage and I took several measurements. Measuring the bumper height to the floor at all four corners. The Bronco leans down to the passenger side and has considerable rake front to back. The lean measurement from driver front to passenger rear is a whooping 3.125" difference. Rake front to back on the driver side is 1.875" and 2.375" passenger side.

 

[gnsteam]

Now that the body won't be going to the body shop until later this year. I've decided to leave the body on the frame for now and go ahead and install the new suspension lift and steering upgrades. I can always remove it again, once I pull the body and start on the frame restoration and 5.0, 4R70w explorer upgrade. That way I can dial in the suspension and enjoy driving it a few more months.

So I started at the rear pulling the rear shocks and factory stock leaf's. The driver side came out easy but the passenger side was another story. I think I found what was causing some of my passenger rear lean. After removing the nut from the bolt at the passenger side leaf front spring mount. I discovered that the head of the bolt was tack welded to the back of the frames spring hanger bracket. And the outside side of the bracket had what appeared to be a larger thick washer welded to the outside of the bracket. See pictures below. Luckily I was able to get a Dremel with small cut-off wheel in there to cut the head free. Once the bolt was removed. You could see why it was welded. The inside hole of the bracket is wallowed out so they welded it in to hold it in place. So at some point in the Broncos past. The front spring bushing must had failed causing damage to the bracket. For now I'm going to drill out the back side of the bracket. And make a flange washer on the lathe to place in the hole in the bracket. I will replace the spring hanger during the frame restoration.

So both leaf springs are out and I called it quits for the day. It was a hot one, 95 and 68 dew point.

 

[svastano]

Great Progress!

 

[gnsteam]

Started the tear down of the 96 Explorer 5.0, so I can send it off to the machine shop. The 4R70W is ready to go to the rebuilder as well.

 

[gnsteam]

I installed the Duck Tuff 2.5” rear leafs with Mig’s rear shackles. I still need to install the Helwig rear sway bar setup but I decided to move onto the front end. Because I’m still waiting for the rear Eibach shocks.%)

 

[Rox Crusher]

Hey Fred great to see you starting your upgrade project.

I’m starting to plan similar changes to mine and will watch your thread updates.

Good luck with the project !

 

[jmangi62]

Good looking rig you got there bud. That's a ambitious project. I'm just stuck in the muck at the moment, my fitech took a crap on me. This is the only issue keeping me from getting on the road after a 5 yr total restomod. I even painted the sucker myself. But I might be going to a color change, the limestone just didn't turn out like I had hoped. Heres a couple pics.

 

[gnsteam]

Hi Rox, thanks. My project has been a log time coming. So glad to be making progress. Be sure to post up your upgrades, your 77 is one of my favorites.

 

[gnsteam]

Good looking rig you got there bud. That's a ambitious project. I'm just stuck in the muck at the moment, my fitech took a crap on me. This is the only issue keeping me from getting on the road after a 5 yr total restomod. I even painted the sucker myself. But I might be going to a color change, the limestone just didn't turn out like I had hoped. Here's a couple pics.

Hi jmangi, My project has been in the planning for a long time, finally getting to it. Have you considered using Explorer EFI? I'm going that route, even though I don't know what I'm doing. Luckily there is lots of experience and help here on the forum. I've noticed that several others, have struggling with the Fitech system. Hopefully you can get it resolved.

We need to meet up some time. My son and I will be spectators at the Ice Cream Cruise in a few weeks. I will be looking to meet up with Marty (greatguy57078) from South Dakota. He is bring down his half cab street rod Bronco to the show. I won't be able to bring my 76, even if I do finish the suspension. My transmission is on it's last leg, so I can't trust it driving out of town. See yea soon.

 

[gnsteam]

This morning, I finished dis-assembly of the front suspension and un-boxed the new parts. The 2.5" coils, coil cups, T-Rex arms, bushing and hardware. Also a new adjustable track bar with Heim joint at the frame end. Not pictured, I also have the Duff's Heim steering and Helwig front sway bar to install.

Later in the afternoon my son and I ventured over to the U-pull It. Where I picked up another ECM and the Escape mounting box. While there I noticed an Astro minivan in the lot. I may go back for the hydro boost unit still inside.

Here are a few pic's from the day.

 

[svastano]

Nice Progress!

 

[gnsteam]

Nice Progress!

Thanks Steve.

Last night a new bronco buddy and I, attached the T-Rex arms to the Dana 44 and got it attached to the radius arm frame mounts. Making progress.

 

[Rox Crusher]

So your not using their adjustable drop bracket for the Terex Ames ?

 

[gnsteam]

So your not using their adjustable drop bracket for the Terex Ames ?

Hi Rox, I just realized this afternoon, that I had forgotten to order that bracket.%) On order now.

 

[gnsteam]

Hi Rox, I just realized this afternoon, that I had forgotten to order that bracket.%) On order now.

Hey Rox, I think I misunderstood what you were saying about the adjustable drop bracket. If you are talking about the radius arm frame mounts. No I am not using the Duff adjustable mounts. In fact, until today I didn't know an adjustable mount was available. I may look into them when I refurbish the frame later this year. The bracket I was thinking of is the track bar riser bracket for the axle. I need it to raise the trac bar at the axle, to clear the tie rod over heims steer. Which shipped today and should arrive Monday. So out comes the axle again to have the bracket welded at a local shop, next week. I do not own a welder.

 

[rguest3]

The adjustable Radius Arm Brackets are not needed unless you have a lot of lift and need to further adjust caster. Your set up should be good with the T-Rex Arms, 2 1/2" Coils and 4* bushings. Others have used the 7* bushings as well, but it can effect the driveline angles if too much Castor.

 

[gnsteam]

The adjustable Radius Arm Brackets are not needed unless you have a lot of lift and need to further adjust caster. Your set up should be good with the T-Rex Arms, 2 1/2" Coils and 4* bushings. Others have used the 7* bushings as well, but it can effect the driveline angles if too much Castor.

Hi rguest, Thank for the information. I'm going to start with the 7 degree and check for clearance at the u-joints at full droop. I have a slightly used set of 4 degree bushing if needed.

 

[gnsteam]

Today I pulled the front axle back out. So I can take it to a local weld shop for track bar riser bracket welding. Pretty handy having the detachment points at the head unit of the T-Rex arms.

 

[gnsteam]

Last night I prepped the Dana 44, to have the Duff track bar riser bracket weld onto the axle. This morning I dropped it off at a local weld shop.