1969 Bronco Build

[hammer]

Well after years of reading people's build threads I get to do my own now.

Purchased this '69 Bronco Last spring and am just starting to dig into it. Goal is to have a decent looking rig that I can have fun with and take camping and hopefully do allot of long road trips with.

Here's what needs to be done, goal is SOB in late August. (ha, ha, ha,)

- Mustang 5.0L MAF EFI swap - Engine's in. Needs to be wired etc
- ZF tranny - done
- Np205 - done
- Swap out the d30 for a d44 - done
- Front Disc brake swap - done
- 2" body lift - done
- CAGE 5.5" suspension lift - done, went with wildhorses system 7 5.5"
- CAGE Extended Radius Arms - done, went with bronco bob's arms.
- CAGE Double shock hoops - done, went with wildhorses extreme hoops.
- '76/'77 Power brake setup - still to do, have the booster and bracket.
- F150 Power steering setup - box is in, have shims for '78 knuckles just need to install the drag link/tie rod and sort out a steering shaft.
- 4.56's - done, went with 5.13's
Replace front floors - done
- Replace kick panels -done
- Replace front inner and outer fenders - done
- 6 point cage -done
- Exhaust -still to do
- 23 Gal EFI tank - have one. Needs clean up and install
- Custom driveshafts - still to do. Pinion angles need work.
- Blast body and paint it.
- Will be on 35's to start as I have a set.....Now on 37" Toyos

[belmont mild]

wow its like looking in a mirror a month ago interested in pictures of this....

[hammer]

A couple before pics;

[hammer]

Here's what you get when your working on a 38 year old truck;

[hammer]

Floors;

[belmont mild]

looks great but some rust to fix up....

[whitetrashxj]

cooo mang i like them old broncos, make sure to post lots o pics....

[hammer]

Got the 'ole 302 out today. I think Gus likes the Bronco as a roadster:p

[Shogunator]

Got the 'ole 302 out today. I think Gus likes the Bronco as a roadster:p

Nice Chessie. How old? Mine's three and a bit. Just starting to calm down a little.

It's too bad that thing is so rusty. It's not often you find a complete stocker with everything still in its place. It will make a nice project though. Good luck!

[hammer]

Thanks, he's two and a half roughly. I know what you mean about the hyperness. He's an awsome dog, you just have to know how to deal with him. Not for the inexperienced dog owner.

[4Lo]

I had a chance to go into the Abby UCFV mechanics shop last week and saw a reeaal nice '69-'70 Bronco on the lift. Apparantly it was getting it's trans rebuilt. It was in beautiful shape and completely stock. I had a good look at the body while it was up on the lift and could not see any rust. The undercarraige was in nice shape as well for a 35+ year old Bronc.

Just a little fyi

[hammer]

Ordered my kick panels, floor panels, inner front fenders and door posts from Wildhorses today:beer

[4Lo]

So your singing Merry x-mas to me...Merry x-mas to me.

Put the reciept under the tree for the warden.

[hammer]

got the tub braced today

[HSOK]

Love the old Broncos. Good luck on your build!

[jeepxj89]

I had a chance to go into the Abby UCFV mechanics shop last week and saw a reeaal nice '69-'70 Bronco on the lift. Apparantly it was getting it's trans rebuilt. It was in beautiful shape and completely stock. I had a good look at the body while it was up on the lift and could not see any rust. The undercarraige was in nice shape as well for a 35+ year old Bronc.

Just a little fyi

you were in the shop eh? i go to school there . im on the heavy duty side though what day did ya show up? yea that bronc is in mint shape. i think its actually one of the welding instructors vehicles

[belmont mild]

hammer in regards to the zuki 4door post if your interested in another 67 ford bronco mint all togther missing the frame and axles unfortunatley but if you are interested i can add some cash with the trade towards that sammi?


Bump to some nice work on that bronco are you making it stock or crazy?

[hammer]

Did the one man tub pull tonight. Went pretty smooth. Forgot to unplug a couple wires and missed the fuel tank switch. Time to start stripping the frame.

[4Lo]

you were in the shop eh? i go to school there . im on the heavy duty side though what day did ya show up? yea that bronc is in mint shape. i think its actually one of the welding instructors vehicles


I work for the city and was just scoping out water meters on campus. Not sure what day that was.

Bronc's coming along hamer. Looks like you got your work cut out for u in many ways.

[whitetrashxj]

wow that frame looks pretty good still, is that a 2wd bronco?

[Lone Ranger]

Too cool, I've always had a liking for the early Broncs. Too bad I sold that EB44 I had, I'd offer it to you. I have an EB door (drivers side maybe). red in colour. Lemme know if you need/want one. It was left at my dad's place when we moved in so I'll see if I can dig it out again. Cheers

[hammer]

is that a 2wd bronco?

no

Lone Ranger, my doors are good so I don't need one. If you need a home for it I'm sure I can provide.

[Lone Ranger]

Yeah, lemme know if you are interested. Its just sitting there collecting dust and we all know how well doors tend to last on the trail..

[belize]

...looks like a decent find Steve...you didn't happen to buy it on the southwest side of Abbotsford did you?

...your build list looks good...nothing too crazy so you can actually drive it. For what it's worth here's my $.02. I'd consider 5.13s with the ZF and 35's. If you're going to 38's you may even want to consider lower gears. Also, don't get suckered into putting a hot cam into that motor. If you give it the gear it needs it'll pull hard and be super reliable.

...look forward to seeing it on the trail!

[hammer]

Thanks Jared, I'll look into the gears. Your probably right.

I bought it off a guy in Steelhead behind Mission. The trucks passed hands a couple times in the last couple years. First time I saw it was up sylvester rd in mission about three years ago. I was there looking at another bronco he was selling. This one wasn't for sale at the time.

Yeah the engine's just going in stock. My goal is to have the truck done for late August, I'd rather have a driver than a money pit in my garage. They're 225 hp, good enough for now.

Also meant to ask you how the drivers side fender and the battery tray is on your parts rig?

[belize]

Yah, ...take it from me...I'm running 4.56's, 35's and the overdrive tranny. The truck is great on the flat (1700 rpm @ 60 mph) but could use more gear at highway speeds where it's hilly. I think 5.13's are the perfect gear for that tranny and 35's.

[belize]

Oh, I was wondering if it was from Abbotsford...I've had my eyes on one on the other side of town. Are you going to cut it?

[hammer]

Are you going to cut it?

Yup. I'm not a purest. They look terrible and are not practical for my application uncut.

[cracmasterG]

im running 410 with 37" iroks and a c6 with 351HO and i wouldnt go any lower on gears than 4.88 if your planing on driving it on the road lots but for crawling 5.13 would be better for a single t-case just my .02 and im using my b-2 as a daily driver and wish i went with 4.56 but oh well and good luck with the build:beer

[hammer]

Got the frame to a bare state today. Shoulda spent the first half of my day fixing my air compressor. Woulda made thing allot easier. No compressor and no torches, so could'nt get the leafs off. Frame's in pretty good shape. Driver's side body mount is going to need a little fixing but other than that its good.

[hammer]

Spent the day home from work today. Buddy of mine who's a fireman downtown phoned me at 9:00 a.m. telling me not to bother going to work as he left abbotsford at 6:10 a.m. and he was at 160th at 9:00:cwm24:

So that was enough to convince me to spend the better part of my day with an angle grinder and a brush cup in my hand. I think I'm still vibrating.

Anyways got the frame all cleaned up. Flipped it over to do the underside and look what i found;

[belize]

Yup. I'm not a purest. They look terrible and are not practical for my application uncut.

I agree...I'm sure 'ol Henry turned in his grave when they came out with the original fender design...

[belize]

im running 410 with 37" iroks and a c6 with 351HO and i wouldnt go any lower on gears than 4.88 if your planing on driving it on the road lots but for crawling 5.13 would be better for a single t-case just my .02 and im using my b-2 as a daily driver and wish i went with 4.56 but oh well and good luck with the build:beer

Steve's planning on running the ZF 5- speed tranny (overdrive). Your c6 is 1:1 in drive.

[hammer]

I think I'm going to have to teach myself how to weld. The welding is always left up to my dad but he's not exactly running over to my place to do it.

[belize]

Steve,

Call me - it looks like you need a different frame...

[hammer]

I'm just going to fix this one. Obviously I'm not gonna try and weld it myself. Just gotta wait until my dad has some time to come patch it. This is the only bad spot. I'm going to weld some washers around all the body mounts as one of the rears has seen better days and then call it done.

[hammer]

Well finally got a few of the missing pieces together. Picking up my d44 this afternoon. Thanks, Ulysse. Got a hold of an '89 MAF mustang 5.0L. I have to go down to Arlington, WA this sunday to pick it up. Engine only has 100K on it. Car had an interior fire. Getting it with all the stuff I need for $350 USD. So thats $700.....not to bad. Gotta get some $$$ together so i can order my lift and start putting this chassis back together. I got the 2wd f150 ps box that I needed and the wild horses adapter plate as well. Also picked up new side mirrors, door panels, body lift, arm rests and door cups, power brake booster with angle bracket and power brake pedal all off ebay recently.

Anyone got a good driver side front fender? Battery tray? 15x8 or 15x10 5x5.5 rims?

Don I emailed you about that 6 point cage you have for sale but haven't heard back.???

Pic is of the engine I'm picking up.

[belmont mild]

Well finally got a few of the missing pieces together. Picking up my d44 this afternoon. Thanks, Ulysse. Got a hold of an '89 MAF mustang 5.0L. I have to go down to Arlington, WA this sunday to pick it up. Engine only has 100K on it. Car had an interior fire. Getting it with all the stuff I need for $350 USD. So thats $700.....not to bad. Gotta get some $$$ together so i can order my lift and start putting this chassis back together. I got the 2wd f150 ps box that I needed and the wild horses adapter plate as well. Also picked up new side mirrors, door panels, body lift, arm rests and door cups, power brake booster with angle bracket and power brake pedal all off ebay recently.

Anyone got a good driver side front fender? Battery tray? 15x8 or 15x10 5x5.5 rims?

Don I emailed you about that 6 point cage you have for sale but haven't heard back.???

Pic is of the engine I'm picking up.


nice

[hammer]

Well starting to make some progress again. I ordered my extended radius arms from broncobob.com along with mounts and a set of body bushings. Also ordered my lift. Decided to not go with the cage lift and went with a wildhorses system 7 instead. Got the front and rear diffs ripped apart and painted. Going to get 5.13's put in them next week hopefully. Have to pick up my rims on Friday as well. I have the last week of March off so with any luck I'll have a rolling chassis again by then.

[kaptin99]

Hey man I was just wondering how you found your engine in the states?

[hammer]

Craigslist.com You can look in any major city. I scan the vancouver and seattle listings pretty regularly. Found it in Arlington, WA. Used automotive parts tend to be way cheaper south of the border. Cheapest engine I could find up here was $800. I picked mine up for $350 U.S., paid a guy $50 U.S. to pull it and $66 cdn at the border for taxes. It came with all the wiring harness and computer.

[jason26]

who's putting your axles together- re ratio?

[hammer]

Not 100% yet, probably Abby Spring Service. Delt with them in the past and they do good work from my experiences and yah i'm just getting 5.13's chucked in for now.

[jason26]

ya if they are pretty reasonable then that ok, i was just asking cause i do gears at my work.

[hammer]

Well day one of my holidays is in the book. The reconstruction has begun! Did a bunch of work on the frame. Fixed the rust spot and body mounts. Hacked off the stock spring towers and radius arm mounts. Welded on the front shock hoops and the rear double shock mounts. Also got my tires mounted. Have to mock up the front end tomorrow so I can mount the new radius arm mounts.

[TroyM]

I like yer shock hoops good job:welder

[hammer]

Well doesn't look like I'm gonna get a rolling chassis by the weeks end:rolleyes: Got the radius arm brackets mounted as well as the trac bar drop bracket and f150 power steering box bracket. Frame has been primed and it got its first coat of paint today. Diffs are with jason26 to get re geared and new bearings installed. Had to order new c bushings as the polyurethane 7 degree ones that came with my lift won't work with my radius arms. So I ordered stock rubber ones as well as a clutch kit. So she'll get a final coat of paint tomorrow and then hopefully next weekend we'll have a rolling chassis.:D

[kaptin99]

looking really good. I cant wait untill I can start my project. Hopefully by the end of summer and ready for next summer. Just need the funds for my project.

[PhantomEB]

Oh god, not a trac bar drop bracket!!! Plan on that thing ripping right off the frame. Might want to look into a trac bar riser to weld to your diff from Wild Horses?

[hammer]

Never had an issue with my last truck in the three years I had it on there. Bolted through and welded.

[hammer]

Well finally got my chassis rolling again today. Picked up my diffs from jason26, who regeared them and installed new u-joints and bearings. Went with the 5:13's. Nice to have something that resembles a truck again.

[jason26]

hey looks good, i wish i could get back on my heep project. so many house projects right now. are those steelies are they new and if so what were they each?

[hammer]

Used. Bought 'em off a guy on the board here for $80. Cleaned 'em up and painted them.

[hammer]

Well engine and tranny are in. Would hate to have to wrestle the zf in with the body on. Had to do enough prying as is. Don't think the stock mustang headers are gonna work. I'll have to see.....Next step I have to grind out the tail housing on the zf in order to clear the linkage on the np205.

[hammer]

Got the notch in the zf cut out and the np205 mounted. Have to build a side mount for the np205 now.....

[hammer]

Looks like the bc bronco cross member may work with the np205. May be a hair to low, I'll have to get a driveshaft in there and find out I quess. I really hope I don't have to mod it. Worst comes to worse I figure I could raise the tranny mount a bit....what do you guys think?

[hammer]

I think I will have to raise up the tranny mount not only to clear the driveshaft but to have enough room to build a side bracket for the np205. Here are a couple pics of what I have found to be my best bet for a side mount bracket. If anyone has a better idea let me know.

[hammer]

Not allot of progress lately, been landscaping the back yard. But I did get the np205 side mount built. Ended up raising the zf mount up a 1/2" in order to give more clearance for the front drive shaft. Stock mustang headers hit the frame on the passenger side so I ordered a set of hedman long tubes. Should be here soon...

[hammer]

Here's a before and after shot of the front drive shaft clearance. Should be enough.

[Damaged]

Looks good. I don't think you'll have a clearance issue anymore.

[hammer]

Well all Ulysse's talk about just getting it done and enjoying it (while working on it still) instead of grinding away at it for years has gotten the better of me. I tossed the tub back on today. My plan was to go get it blasted and then start all the body work. So I said screw the blasting and I'm going to start the body work on the frame. I must say having the tub back on has really rejuvenated the process for me.

[hammer]

Tossed the cage that I picked up on it to get an overall look. I don't even mind the 35's with the uncut fenders. Must admit I'm a little intimidated starting the body work. My last truck had the body pretty much done so this is going to be my first attempt at major body work. Any tips from the EB guys at where to start, etc, would be appreciated.

[belize]

Gotta say steve...you're making it look easy...nice work. Will you have her ready for SOB?

I'd seriously consider getting the tub dipped once you've got the body work done. This will get at any rust that you've missed (in the seams). I've also heard of some guys galvanizing the body which is really supposed to seal it.

...keep up the good work!!!

[hammer]

Thanks Jared. Defiantly not done for SOB. Between work and crunch time for my wedding I'm surprised I'm getting anything done at all. The tub will come back off once I have all the panels in. Next time I'm taking it to my dad's shop and using the hoist. It was a lot easier to take off than it was to put back on. Then I will do something with it before paint.

The replacing of panels will be a real test for me. Never done it before and my welding is still in the beginning stages.

Picking up a '78 d44 tomorrow to use as a donor for my disc swap. Anyone interested in the rest of it?

[hammer]

got the f150 disc swap done today.

[hammer]

Day 1 of body work. Drivers side inner front fender, kick panel and door post removed. I love spot welds.....

[hammer]

Day two body work. Got one of the floor pans under the pedal replaced. Its spot welded in and done.

[hammer]

I replaced the mounting tabs for the kick panel along the firewall cause they were rotten. Forgot to take a pic but its highlighted here;

[hammer]

Kick panel and inner front fender are lined up and held together with sheet metal screws. Just need to line up the front clip and the hood and make sure everything is sitting where it should before I spot weld.

[hammer]

Body Work Day Three. Got the driver side door post on. Got the rest of the drivers side floor in. Got the cowl lip fixed kinda.....had a 3" rust hole in it and had to replace the lip that over laps the kick panel. Lip turned out good but my patch is something to be desired. My butt welds on thin stuff need some practice:( Happy with everything else so far though. Time to hit the other side!

[blazin saddles]

Hey Hammer looks great!I hope you've thought of folding down the windshield and taking out the hinge.That's where I found more rust after I did everything your doing. Then I sent it out and sandblasted it.

[hammer]

Body work day 3 1/2. Got a couple hours in after work yesterday. Managed to get the passenger side floor removed and door opening braced for the post removal. I was happy to see that the cowl under the plastic heater intake box looks to be in good shape. I thought for sure it would be shot.

[hammer]

Hey Hammer looks great!I hope you've thought of folding down the windshield and taking out the hinge.That's where I found more rust after I did everything your doing. Then I sent it out and sandblasted it.

Thanks man. You removed all the spot welds through there and found rust underneath? Or do you have one of the earlier bolt on frames? If the hinge and spot welds showed no signs of rust I wouldn't dream of taking it off just to check. There's 70+ spot welds along there.

[blazin saddles]

Well Steve...my truck is a 74, so yes I drilled out everyone of those f#@%$*g spot welds!:D :D :D But I just remebered it was after the sandblasting.The guy that did it for me said that the bronco's he'd seen locally all had it under that steel hinge.The moisture get's under,stays and then starts to rot.What I did after removing the hinge and putting new metal in, was put in nutserts then put in a stainless hinge and put in countersunk screws.If anything happens you can always remove the whole windshield.I bought the hinge from Faucher Industries in Poco.Perfect width just alittle too long.Good luck!

[hammer]

Got another couple hours in after work today. I have all the sheet metal removed out of the passenger side. With all this removed I can look up under the windshield hinge and it looks good. Inner rocker at the front where the kick panel overlaps looks worse on this side. Pretty sure its gonna have to go as well. My brace on this side has me pretty pist off though. Thought I could move the vertical portion back to the second body brace and that would allow me to get the front floor in without having to move it. With it that far back I have a little flex going on though. Not a lot but enough to make things more interesting then they needed to be.

[Maelthra]

Looks like fun, I've always liked EBs.

[blazin saddles]

Hey Steve I just remebered another area to look at.I found a bunch of hidden rust behind the vent lines for the rear tank.Don't know if you have these lines on your 69.They are metal lines that are up tight to the seam of the bed and the drivers rear inner fender.Good to hear you have no rust under the hinge:D

[hammer]

Funny how these updates get farther and farther apart.....

Wedding's Done!

Just when you thought you were in the clear.........baby #2's on the way:shakehead:

So time to go hard. I picked up the rest of my body panels at the border this week. Short term goal is to have the tub back from the blasters by remembrance day. I'm working nights for the next 2 months so hopefully I can get motivated during the day to get some **** done.

[hammer]

Well went to do some welding today and found out I left my argon tank open and it was empty....... Hard to find argon on a Sunday.

So I got the passenger floors mocked up and drilled out for spot welds and screwed in place. Fabbed up a new inner rocker panel and removed the heater box.

Had to order a new passenger side kick panel today as well. Turns out the one Belmont Mild sold me a year ago is complete garbage. Fit is terrible, no holes/nuts mounted for door straps/dash and to short at the bottom. I hope someone made it and thats not what a supplier is producing.

[blazin saddles]

I bought mine from Jeff's Bronco Graveyard.Fit perfect,all the holes were there.It was built from the orginal jig and it has a galvinized coating.

[okor]

Looking good. Makes me miss mine.

[hammer]

Here's a couple current pics;

http://classicbroncos.com/forums/attachment.php?attachmentid=111502&d=1223237400

http://classicbroncos.com/forums/attachment.php?attachmentid=111515&d=1223238093

And a link to the build progress although I haven't touched it in two months since undercoating it and putting the tub back on for the last time:welder

http://classicbroncos.com/forums/showthread.php?t=114457

Let me know what you think:beer

[jeepxj89]

looks good. one thing i would do though is flip the tie rod ontop.

[hammer]

looks good. one thing i would do though is flip the tie rod ontop.

Thanks, yes that will be one of the things that I eventually get to. Have to order one of these;

http://www.wildhorses4x4.com/product/Adj_Drag_Link_P_S_F100_Kit/Power_Steering_Kits

because I'm running a '70's 2wd PS box. Then I'll flip it all around and set it up properly.

[jeepxj89]

or you could just get two pieces of tube, get each end threaded and run chev 1t joints. it works awesome

[hammer]

or you could just get two pieces of tube, get each end threaded and run chev 1t joints. it works awesome

Sure. I'm not very resourceful like that. I'm a chef by profession so all this mechanical stuff is just a hobby for me. Unless I learn it step by step on the internet I usually just end up ordering exactly what I need because I know it will work. Sucks because I end up paying way to much for things. I wish I had all the know how to toss stuff together and make it work. Things are a lot easier since I got a welder and taught myself how to use it. I can be a little more creative. Unless I find a write up on something with part numbers and step by step directions I just stick to what I know will work.

[jeepxj89]

i knew of a good thread that was very descriptive on doin the 1 ton tierod swap, its the one i used when i did it to the front d44 on my jeep. ill see if i can dig it up

[Ulysse]

Steve,

The one ton stuff is the way to go...

You will need two of these:

http://completeoffroad.com/i-123283-tie-rod-end-bushing-dana-44-60.html

then you can buy the kit and do it your self...

http://completeoffroad.com/i-124127-tie-rod-drag-link-kit-dana-3044-and-60.html

Or you can buy the finished thing instead...

http://completeoffroad.com/i-122850-tie-roddrag-link-71-75-bronco-1-12-d-o-m.html


Ballistic Fabrication has a good parts kit too...

http://www.ballisticfabrication.com/TRE-kit-includes-ES2233L-1-ES2027L-1-and-ES2234R-2_p_114-1203.html

[hammer]

Good info guys thanks. I'm sure I can work something with that. Guess I have to quit being a slave to the bronco vendors.

[jeepxj89]

the second link ulysse posted looks like an awesome deal. you dont need the tapered inserts, just get a 7* reamer and ream the knuckle from te top down, checking every couple of seconds for the fit of the tie rod.

[blazin saddles]

Hey Steve your bronco looks awesome!So.... what colour is it going to be painted?

[hammer]

Hey Steve your bronco looks awesome!So.... what colour is it going to be painted?

Thanks,


Its going to be Dark Shadow Grey Metallic. Its an '02 ish ford color. Black accents with an orange pinstripe. Bought the paint two months ago but I'm getting a transfer at work in January and we opened a new store last October so I've been to busy.

[shakey84cj]

Nice build Hammer. Taking your time really pays off 'eh? I'm glad to know that I'm not the only one out there with a 2+ year ongoing project too, lol.

[hammer]

Nice build Hammer. Taking your time really pays off 'eh? I'm glad to know that I'm not the only one out there with a 2+ year ongoing project too, lol.

I'll let you know when I'm done if it pays off......

My dad took 22 years to complete the resto on his '69 Dart 340 GTS convertible. With that as comparison I think I'm making pretty good time. I've gone from getting angry that its not done to just happy at the prospect that one day it might be done. If I spent 1/2 as much time working on the truck as I do on these sites I'd be better off.

[shakey84cj]

My dad took 22 years to complete the resto on his '69 Dart 340 GTS convertible.
What the hell? Did he just buy it new and figure it wasn't quite good enough? LOL, that's quite the buildup I'd imagine.

If I spent 1/2 as much time working on the truck as I do on these sites I'd be better off.
You, I, and many others I'm sure, lol.

[hammer]

What the hell? Did he just buy it new and figure it wasn't quite good enough? LOL, that's quite the buildup I'd imagine.

Nope that's what happens when you have kids and your wife won't let you spend one red cent on your project. He bartered for 22 years to get that car done.

[shakey84cj]

Nope that's what happens when you have kids and your wife won't let you spend one red cent on your project. He bartered for 22 years to get that car done.

This is why man invented vasectomy's... one snip and you're on your way to many completed projects. If you don't tell her, she'll just think it's something wrong with her and you're home-free!

JK guys, I wuoldn't trade my little boy for any Jeep. The wife... hmmm.

[hartbronco]

It looks good !!!! keep going on her it's worth it !! Mine was alot more rusty and I pulled it of in two years . All the fun was in the build for me until I drove her for the first time !!!! good times ... :beer_cheers: