Stutsmo's 67 build.

[fatboy]

Well, It is decision time. I spent the last week trying to get the Sniper dialed in and buttoning up all the small items that need to be addressed. Almost everything on the Bronco I have 100% confidence that it is worthy of a Roadtrip. The sniper is my only doubt..... I am about 80% confident we wont have any issues with it but there is always that 20% that makes me hesitate. I have over a hundred miles on it and it runs really good with the exception of it runs about 50 rpm higher than where ever I set the idle and the IAC seems to fluctuate wherever it wants to. But other than that the Bronco seems to run and drive fine. I am pretty sure that tomorrow we will be headed to Townsend in it. I worked pretty hard o. It to let a few nerves get in the way of us getting it there. Wish us luck and say a prayer!
Townsend or Broke. Hopefully not both!
Pic of my first test drive 40 mile round trip to our lake property.

Cute rig, safe travels! It will be fine, just enjoy the experience.

 

[tasker]

SAFE TRAVELS BUDDY!!! SO DAMN PROUD OF YOU!!!

 

[Stutsmo]

Well, the Bronco made it to Super Celebration ’23! We were not able to drive it because I just didn’t feel like it was ready for that long of a trip so we put it on the trailer and hauled it down there. The biggest problem I am having with it is that it has a miss. It is stumping me because everything is new, however I found a new plug wire that got too close to my header and got burnt so I replaced it. That didn’t fix it so we made a second trip back to Pigeon forge to get a set of spark plugs. It’s a lot better but still missing. My RPM is set at 600 on my Sniper display. I rarely ever get that low it fluctuates between 630 and 650 pretty consistently. Also my IAC will not stay consistent. We have several times set it and cycled the key like we are supposed to and then come back out the next day and it is like we didn’t set it. So there is obviously something not right. I thought I did a pretty through job on the install, but I guess I have to go back over it for the hundredth time and make sure to dot my I’s and cross my t’s.

Over all I am very glad I went, we had a great time. We were able to drive the Bronco on 2 runs through the Foot hills loop and also through Cades Cove. Plus a few trips to Pigeon Forge. Leading upt to the events It was 6 weeks of WORK for FOUR days of FUN with may new memories made. I’ll attach a few pics to show people that are still building their Broncos how much fun you can have when you get them going!

Then stay tuned because, well we are 11 years into this build and I feel like I am just getting started. My first drive through the mountains got me to thinking so now we have a few more upgrades to install!

Hopefully be done with them in time to attend the Bronco Takeover in MI in August!

 

[Stutsmo]

Pics added.

 

[Stutsmo]

This next upgrade has been part of the plan for quite some time. Been asking questions and rounding up parts for a few years now. I was trying to get to it before going to Towsend this year but after getting into the Engine and Sniper install I decided to get those projects up and running before going all the way with this upgrade.
Since this Bronco is shared with my Brother compromises have to be made he LOVES the 3 on the tree shifter and is partial to manual transmissions in general. If it were up to me I'd be happy with putting an automatic in it. Both of us agree that overdrive would greatly benefit us for how we intend on driving the Bronco. It will see a lot of highway miles. I'll be driving it to Bronco events across the country and he will be taking short weekend vacations in it.
We agreed that the ZF5 speed will work for what we want.so about 6 years ago we picked up a 1988 F250 for $500 that was beat pretty bad but it had a ZF So we brought it home. I found a NP205 For $50 about 5 years ago so I grabbed that up also. So fast forward to this February when I started thinking about trying to get the Bronco to Super Cel I pulled the core stuff out and decided to get them rebuilt so that the Bronco will have an all new drive train in it.

I decided not to use the Np205 because of 2 reasons. Number one it's just to big and heavy. Number 2 I would have to cut up my exhaust. So before I could change my mind I ordered the adapter to put the Dana 20 behind it.
Trying to find someone to rebuild the trannny or transfer case turned out to be a chore. I settled on taking a core transfercase to Broncograveyard and had them rebuild it for me. The ZF was sent to High Impact Transmission and Gear and that core was swapped out for a remanufactured trans.
So with these being taken care of by rebuilders I could concentrate on getting the Bronco to super cel. Now that I'm back it is time to tear into it and hopefully get it back on the road in less than a month.

I got the ZF, adapter and Dana 20 bolted together today.

 

[stupidboy]

How was the trip ?

 

[Stutsmo]

How was the trip ?

It was so good we reserved our rooms again for next year. We had a great time!

 

[gnsteam]

Great to here that you made it and had a good time. I'm still looking forward to my first trip to Super Celebration. Hopefully next year.

 

[Stutsmo]

Great to here that you made it and had a good time. I'm still looking forward to my first trip to Super Celebration. Hopefully next year.

Make hotel reservations now. It is more likely you will make it a priority to go. Also hotel space will be at a premium next year because the Rod run in pigeon Forge is the same week. So you dont want to wait to long to get a room reserved

 

[gnsteam]

Make hotel reservations now. It is more likely you will make it a priority to go. Also hotel space will be at a premium next year because the Rod run in pigeon Forge is the same week. So you dont want to wait to long to get a room reserved

Thanks for the heads up. I better get to booking a room this week.

 

[NCSUWoj]

Well, the Bronco made it to Super Celebration ’23! We were not able to drive it because I just didn’t feel like it was ready for that long of a trip so we put it on the trailer and hauled it down there. The biggest problem I am having with it is that it has a miss. It is stumping me because everything is new, however I found a new plug wire that got too close to my header and got burnt so I replaced it. That didn’t fix it so we made a second trip back to Pigeon forge to get a set of spark plugs. It’s a lot better but still missing. My RPM is set at 600 on my Sniper display. I rarely ever get that low it fluctuates between 630 and 650 pretty consistently. Also my IAC will not stay consistent. We have several times set it and cycled the key like we are supposed to and then come back out the next day and it is like we didn’t set it. So there is obviously something not right. I thought I did a pretty through job on the install, but I guess I have to go back over it for the hundredth time and make sure to dot my I’s and cross my t’s.

Over all I am very glad I went, we had a great time. We were able to drive the Bronco on 2 runs through the Foot hills loop and also through Cades Cove. Plus a few trips to Pigeon Forge. Leading upt to the events It was 6 weeks of WORK for FOUR days of FUN with may new memories made. I’ll attach a few pics to show people that are still building their Broncos how much fun you can have when you get them going!

Then stay tuned because, well we are 11 years into this build and I feel like I am just getting started. My first drive through the mountains got me to thinking so now we have a few more upgrades to install!

Hopefully be done with them in time to attend the Bronco Takeover in MI in August!

Sounds like a fun trip! Congrats on your hard work getting the bronco ready! We installed a sniper set up on my brothers bronco a few years ago. I had a heck of a time with the IAC sticking on me. For the life of me I can't remember what we did to fix it. I know I called the tech line and went through the troubleshooting with them on it. I feel like we replaced it, but I can't remember. Sorry I am not much help, but I bet you have everything installed correctly, it is just sticking on you. I would call them and talk through what it is doing. I am pretty sure I did some datalogging and sent it to them as well.
The handheld would show the IAC was closed, but clearly it wasn't and you could hear it sucking air like crazy.

 

[Stutsmo]

We started the ZF install. Been working on it a few hours a night and we feel like it is moving along a little better than our normal pace as far as projects go. Cut the hole in the tunnel according to the instructions off the BC Broncos site. Installed the clutch master from a tech article on this site. Bought another new clutch and installed it. Painted up the BC Broncos crossmember and installed it. Then got the complete unit installed in the Bronco .... well sitting where it is supposed to be in the Bronco is a better way to say it. We still have to cut the hole a bit bigger for the twin sticks to fit. And also the crossmember needs some shims to fit perfectly in our frame. Over all so far so good. I'll update with the finish pics when we are done.

 

[tasker]

looking good buddy!

 

[Stutsmo]

Had to cut the hole a bit bigger for the twin sticks. I was hoping to avoid doing that but its done so I cant go back. My Brother is going to make a cover plate for it like the big 78-79 Broncos have on the lazer at his work to cover it up.

Fabricated a "Shim" to fit between my drivers side frame rail and the BC crossmember. Had to go buy some longer hardware to get it all bolted up. I believe this is the same crossmember as the 6R80 because it dont look like the ones I have seen in the older build threads on this site.

Also got all the fluids to fill the ZF And the clutch master so I am hoping to be done with this part by the end of the weekend. All that will be left is to buy new drive shafts and get the floor put back together.

 

[Stutsmo]

Been a long few weeks. Working 10 hour days and the not doing much else besides working on the Bronco a few hours a night after eating dinner... But I am happy to report that it is almost done. I still have to get new exhaust bent up because the crossmember is in the way so the current exhaust wont tuck up under it like I want it to. I am also still waiting on my guage cluster refurb to be done. It is supposed to be here wednesday.
I'll attach pics of what I have been up to. I got the new wild horses fan shroud Installed. My Brother and I collaborated on mocking up and fabricating a 12 guage removable tunnel cover. Installed Two brand new driveshafts.
Doesnt seem like alot for 2 weeks worth of evenings but I Am happy with the results so far.
If I can get someone to bend up the exhaust in time my wife and I will be driving it 3 hours north next weekend to the Bronco take over.

 

[tasker]

Nice job stuts!!!

 

[Stutsmo]

Thanks Randy!

 

[Stutsmo]

I got the cover plate and the shifters installed for the ZF 5 and rigged up a temporay exhaust just in time to get the Bronco to the exhaust shop to get a new "Y" pipe made. (this was last Tuesday 5 pm) They said "Leave it overnight we will keep it inside and get you an estimate in the morning". The next day they called at 9 Am and said "yep we can do it. for $1574.89. I said nope... Thats way too much. So I left work at 1pm on Wednesday and started hunting for a place to do it. Keep in mind I am trying to get it done by Thursday because I wanted to drive it to the Bronco Take over and leave on Thursday. After going to 3 places with no luck I tried a fourth place and it was suprisingly agreeable. They always have a hundred cars out front so I didnt think I had a chance but they said they would leave it inside overnight and have it done Thursday morning for $670. They kept their word so at 6 pm we were on our way to the take over at silver lake. Its the farthest the Bronco has ever been from home and the longest I had ever driven it at one time. We made it there, drove it around town for 2.5 days and made it home without major breakdowns! pretty happy with ole "Luke". He performed really well for his first road test.

Thats not to say our trip was without issues...... but I am just glad we got there and back in one piece!

 

[Stutsmo]

Getting ready for the Broncos next road trip. Headed to super Cel in a few weeks. I put it away last October with a list of stuff to tweak when I got time over the winter. We'll I never got time untill now. Short list is to figure out why my sniper unit isn't quite running like I had invisioned it would. I also need to put a new wiper motor on it. It took almost 4 months from the time I bought the wiper motor untill I actually recieved it.... anyway I have it now so now I need to install it. Then last but not least I need to dig my doors out that are painted but need to have all the internal parts installed. I don't really want to put the doors on it but the possabiltity of a 9 hour drive in the rain without doors in 45 degree weather doesn't sound all that appealing to drive through. I got some pics of the doors and waking up Ole Luke from his winter sluber. Check out the paint on my donor doors. These belonged to a buddy of mine at one time and the striping on his Bronco was a site to behold. I am thinking about keeping the skins intact and using them as wall hangers.

 

[tasker]

LIFT off hinges? maybe you take them on and off as needed?