Wanted a Bronco (West Coast Bronco Build Thread)

[kholding]

I thought I would start documenting this crazy experience I am going through right now called "building a Bronco". No, I didn't say "REBUILDING" a Bronco,... that might have been easier (Not EASY, but maybe EASIER). Let me explain; I looked for months with all of my inexperience to find the perfect "starter" Bronco. I never did find that great deal and then I stumbled onto an add for a guy selling a 1971 Bronco frame (just the frame, NOTHING ELSE!) with title for $100. And I thought to myself, why not start from the ground up? I can piece this thing together with all the parts I choose!... That is how this story begins...

 

[kholding]

Turns out the frame I had bought for $100 wasn't "perfect" for the build I was planning. I hooked up with John/Don over a West Coast Broncos and they found me a nice donor frame and a set of axles (Dana 44 front, Ford 9" from a '77 for the rear). They cut off all the old brackets and prepared for their "extended radius arms" and shock hoops.

 

[kholding]

WCB has done a great job so far with helping me with all of the options out there and things I need to hunt for. I set out to find an engine/transmission and a good tub... Here is what the chassis looks like so far with the radius arms and shock hoops.

 

[kholding]

Onto the engine... with so many options out there and talking to quite a few people here in the Tech Forum, I decided to go with a 351W "roller" motor I found at a local salvage yard. I was told it was from a 1995 Bronco and had 64k when it was pulled. $500 later I had it in the back of my truck. I really wanted to get a motor from a running vehicle but to find one at a reasonable price without a ton of issues wasn't happening for me. I took a chance and bought it. I decided to take it to the machine shop and have them "freshen it up". They broke it down, checked tolerances on everything (didn't need boring!). New rings, timing chain, bearings, etc... I pick it up tomorrow. I bought a GT40 lower from a Lightning and plan to use a GT40 upper. Looking for everything else...

 

[kholding]

I was originally going to go with a C4 trans from the guys at WCB but had a lot of discussion here in the forum about the 4R70W. I figured I didn't want to get the whole thing built and then realize that I should have put a better transmission in for the type of driving this thing will see. I searched around and found a '98 4R70W from a F150 4x4 for $300 in eBay. After talking with the seller, he believed this was "dealer surplus" and had never been used. I took a chance again and bought it. The seller called me an hour later and said he was driving out to Vegas in 3 days and would deliver it to me at no additional charge! I took it down to the trans shop this week to have the Advanced Adapter installed and to check it out. The shop confirmed that it was a brand new transmission. I felt pretty lucky after that.

 

[Kyle.malone]

All I can say is LUCKY! good luck with your project!;D

 

[tasker]

98 f-150 i belive will have a different bell housing pattern that the 351 you are using...i'm not at work to check this but just make sure before you get too deep. LOOKING GREAT SO FAR THOUGH!

 

[kholding]

It has the correct bell housing. Checked several times and then once more for good measure! I thought I was going to have to add clutch plates but turns out the 4.2L version of the 4R70W ('98 and later) has the same number of plates as the 5.0 version.

 

[kholding]

Tub time! Looked all over the place for a decent tub and kept finding rust buckets. Finally ran across an ad for a bronco body for sale in Salt Lake City. Turns out it was a body shop that had begun some work on it and then the owner skipped out on paying him. The shop owner hadn't done much other than sandblast it and order some new parts (new grill, front fenders, floor pans, rear quarter panel and striker post). I was able to wiggle the shop down to $1600 for everything (it was bolted to a frame that looked like it had been attacked by a kindergarden class with cutting torches!). I trailered it home and brought it to some local body shops that do restorations. The first quote I got was for $5000!!! I thought I had missed something really bad... This was a nice tub. The only rust I could find was floor pans, minimal on the door posts and minimal in the bed by the back of the wheel wells. I thought really hard about selling it and even listed it here in the classifieds for a day. I had another guy come look at it and he was WAY less. Third shop was consistent with the second guy. Wheew... I feel better now. Ordered all new steel for the mentioned areas and had it all replaced. They are seam sealing it over the next few days and then etch primer. Here are before and after pictures.

 

[kholding]

The guys at WCB have the basic rolling chassis mocked up for me now (family roll cage is sitting upside down on frame in picture). We are waiting for the tub to get done at the body shop so I can bring it down to use to fab up the front tubular core support. Once that is done, we will break it all down and paint/powdercoat the frame and suspension pieces. I also just ordered 17" Walker Evans beadlock wheels in matte black along with 35" BFG KM2's. I also got in on the "mass buy" for the Baumann/Optishift transmission computer. Thanks again for getting that together guys. Great deal!

 

[mavereq]

looks good man

 

[addicted]

That looks really awesome. Im doing pretty much the same thing. Starting off with a set up rolling chassis and then popping the body on when Im done. Im curious about those shock hoops. Do they tie into eachother across the engine compartment? Another member and I were wondering. Seems like with the frame mounts being able to pivot on bushings that all the stress would be on the welded point on top of the coil bucket. Dont mean to high jack. Just curious.

 

[kholding]

WCB does tie the shock hoops together if you like. They have several examples in their "projects" page. I am waiting until I get the engine situation all worked out so we only have to do it once! Just picked up my engine from the machine shop. Will post pics in a bit.

 

[clarrance]

Tub time! Looked all over the place for a decent tub and kept finding rust buckets. Finally ran across an ad for a bronco body for sale in Salt Lake City. Turns out it was a body shop that had begun some work on it and then the owner skipped out on paying him. The shop owner hadn't done much other than sandblast it and order some new parts (new grill, front fenders, floor pans, rear quarter panel and striker post). I was able to wiggle the shop down to $1600 for everything (it was bolted to a frame that looked like it had been attacked by a kindergarden class with cutting torches!). I trailered it home and brought it to some local body shops that do restorations. The first quote I got was for $5000!!! I thought I had missed something really bad... This was a nice tub. The only rust I could find was floor pans, minimal on the door posts and minimal in the bed by the back of the wheel wells. I thought really hard about selling it and even listed it here in the classifieds for a day. I had another guy come look at it and he was WAY less. Third shop was consistent with the second guy. Wheew... I feel better now. Ordered all new steel for the mentioned areas and had it all replaced. They are seam sealing it over the next few days and then etch primer. Here are before and after pictures.

$5000 seems very reasonable for what you are having done. I just spent $7100 for mine. I did all the panel replacement myself, I had it media blasted, an I delivered it to the body shop on a rotisari. The paint supplies alone cost $2500 - $3000.

 

[kholding]

That price didn't include paint!!!

 

[kholding]

Picked up my engine today. They said it was clean and appeared to be low mileage. Had to replace one piston (said it was .002 off at the base so they ordered a new one). They said the engine had "lightning" pistons? Had to use different rings and piston. Hmmmm? Didn't make sense to me. I was happy with how it turned out, now just have to get it back together again.

 

[kholding]

Got the Advanced Adapter mounted to the transmission. I even went back and measured the bell housing AGAIN after Tasker's comment that it might be the wrong one! Thankfully it is the right one. Now I just need to have the crossmember cut/fab'd to mount the engine/trans.

 

[englewoodcowboy]

Keep going man! Great job so far! Its making me rethink my tranny a little, I scored a donor car with a fresh AOD... It would be close money wise to convert from manual to auto vs swapping in an NV3550... so many decisions......

 

[kholding]

Thanks Cowboy,...I'm learning a lot, mostly from everyone here!

 

[mattt]

That's going to be a nice Bronco when finished. You can't go wrong with John and the guys out at WCB. Good luck with the build!