Early Bronco beater

[Gubni]

I'm going to build a budget bronco. Nothing fancy, but something to have fun with. My goal is less than $1000 budget and 3 days.

77 EB body and frame - free

I traded for some 35" tires tonight - cost $100 (assuming I can sell his 8 lug rims)

3" lift springs $50

3" lift blocks - free

stock 302 that hasn't run in 10 years - free

NP435 and 205 - free

77 F-150 D44 - $250

9" rear with spool - $125

15x8 5x5.5 rims - $40

radiator, fan, and shroud - free

misc brackets and adaptors - $150

If all goes well I hope to do this the 27, 28, and 29th. I supply pizza and coke for those that want to help. I'm just not sure on the date though. I've got a project in the shop that I have to get out first and I'm still waiting on some parts for the EB.

I'd love to hear your comments about what parts or projects that I've not thought about yet.

Major projects are:

Dovetail and reconstruct rear (rusted out) I want to cut out all the floor behind the seats then narrow the rear maybe a foot or so. I've got a sheet of 1/8" diamond plate to use as the new floor. We will also need to build some sort of permantent tailgate. Needs to be simple and light. We will eliminate the wheel wells while we are there since I'll be using full width axles. (Jarret?)

Rebuild and regear both axles. Unless the bearing is totally shot I will reuse them. I plan to put new seals in the front though.

Install engine and accessories.

Get engine to run.

Pull manual brakes and manual steering from other bronco and install it on this one. Later those will get upgraded, but cheap and easy for now.

C-channel bumpers - I like something that I can hit hard with no worries. Might not look pretty, but so long as it does the job. (Marcus?)

[r1ng3l78]

i told ya i'd do the suspension 8) i'm thinking an "early hillbilly" motif for this one :lol:

[Gordon]

...... i'm thinking an "early hillbilly" motif for this one :lol:

Yup, and he can always borrow my camper - the one I was going to loan Cindy.

[Rtaylor]

Shawn,

Cool project, but there is something that you must put on your projects list before you ever even consider taking it off-road.

Replace the rag joint on the steering shaft with a universal joint. I destroyed my original rag joint on my first outing and replaced it with a brand new rag joint. It was tore apart on the next outing. I then bought a new Chevrolet steering shaft with a universal joint and slip joint through Ebay for about $20. A little fabrication work, and I never had another problem.

Trust me, it is pretty intense when you start down a hill and the steering wheel suddenly has no effect :shock: Fix this issue before you hurt yourself or someone else...

[Gubni]

Yeah, I know all about those. I have a steering shaft collection for that reason.

[HotRodYJ]

See anythign can be fixed just using the right parts. A little Chevy stuff usually helps any situation 8)

[Gubni]

See anythign can be fixed just using the right parts. A little Chevy stuff usually helps any situation 8)

:duckie:

[redwings5]

id love to lend a hand. my expeirence is limited but i would like to watch and see how you all do what you do.. plus i can move things hold things or fetch tools! :lol:

[SamuraiGuyTN]

id love to lend a hand. my expeirence is limited but i would like to watch and see how you all do what you do.. plus i can move things hold things or fetch tools! :lol:

And don't forget he is wicked good at ordering Pizza :lol:

[Rtaylor]

See anythign can be fixed just using the right parts. A little Chevy stuff usually helps any situation 8)

:duckie:

The best solution for the brakes is to install Chevy disks up front!!! I feel so much better finally getting that off of my chest!!! :smokin:

[Gubni]

See anythign can be fixed just using the right parts. A little Chevy stuff usually helps any situation 8)

:duckie:

The best solution for the brakes is to install Chevy disks up front!!! I feel so much better finally getting that off of my chest!!! :smokin:

Yeah, that's what I want to do. Spend extra money and time to put shovy stuff on it. Why don't you go play with your jeep you trator. :P

[Rtaylor]

See anythign can be fixed just using the right parts. A little Chevy stuff usually helps any situation 8)

:duckie:

The best solution for the brakes is to install Chevy disks up front!!! I feel so much better finally getting that off of my chest!!! :smokin:

Yeah, that's what I want to do. Spend extra money and time to put shovy stuff on it. Why don't you go play with your jeep you trator. :P

Seriously, you can call it Dana 44 parts. That's what I did when I was in denial :lol:

[SamuraiGuyTN]

fight..........fight..........fight.........fight fight fight. J/k and thus the on going baddle between the bow tie and Fords (at least they circled the problem) continues :lol: :lol: :lol:

[Gubni]

See anythign can be fixed just using the right parts. A little Chevy stuff usually helps any situation 8)

:duckie:

The best solution for the brakes is to install Chevy disks up front!!! I feel so much better finally getting that off of my chest!!! :smokin:

Yeah, that's what I want to do. Spend extra money and time to put shovy stuff on it. Why don't you go play with your jeep you trator. :P

Seriously, you can call it Dana 44 parts. That's what I did when I was in denial :lol:

Yes, I know it can be done, but since my D44 is already disc brake I have no need to put chebby parts on it.

[Rtaylor]

fight..........fight..........fight.........fight fight fight. J/k and thus the on going baddle between the bow tie and Fords (at least they circled the problem) continues :lol: :lol: :lol:

Shawn knows I'm just kidding. I built a '73 Bronco and have already experienced the things that I am joking with him about. I'm a long time Early Bronco fan. I would still have mine if Harlan had not revealed the weak points in it's frame.

[SamuraiGuyTN]

fight..........fight..........fight.........fight fight fight. J/k and thus the on going baddle between the bow tie and Fords (at least they circled the problem) continues :lol: :lol: :lol:

Shawn knows I'm just kidding. I built a '73 Bronco and have already experienced the things that I am joking with him about. I'm a long time Early Bronco fan. I would still have mine if Harlan had not revealed the weak points in it's frame.


Oh i know. I just thought it was funny how you guys were going back and forth. I do like the early bronco. There is a guy in my neighborhood that has a really nice one. I think its blue with a white stripe.

[Jazzman31]

Im you engine man. I can probaly get that thing to run. I'm in depending on track schedule. And I will help with what ever else. Always need to learn more.

[Gubni]

Ok, I got the word from the guy helping me with the current project. It will be done next week, so we are on for the 26th - 28th.

Fridays goal - rebuild axles and get them installed. I will work on that mostly. I'd like to have someone else working on dovetail the rear. Welder experience required.

Saturday I'd like to get the motor, trans, and steering installed.

Sunday make it all work together and run.

This is going to be so much fun. Thanks for all the help. Who can show up when? That way I can sorta plan things out a little.

[Dino1967]

don't know my work schedule yet but will if i can

[Hokie_YJ]

I should be able to be there all three days.

[R.E.C.O.N.45]

there is a guy near where I live that has serveral broncos he is selling. Maybe a good source for some parts. I used to have an Early Bronco. I am still a member of classicbroncos.com. That is a great place for info and parts.

[Gubni]

there is a guy near where I live that has serveral broncos he is selling. Maybe a good source for some parts. I used to have an Early Bronco. I am still a member of classicbroncos.com. That is a great place for info and parts.

Get me his info pls.

[R.E.C.O.N.45]

Here is his email and address. also here is a link to 1 of the 3 bronco he is selling. I am Kidduniversity on there. Hope it helps.


wreckrebuilder@aol.com
704-507-2453
http://classicbroncos.com/forums/showthread.php?t=94820

[Gubni]

Thanks, his half cab could be pretty nice.

[chaser]

I am up to help ya out shawn I hadnt been over in a while itll feel good to get dirty :grin:

[Dino1967]

ive gotta work saturday :(

[Gubni]

Going to start on it tomorrow. It's in the shop now. I've got to ship some tires in the morning. If that goes well I should be ready to start by 10am. I've got to meet a guy in Asheville tomorrow about 8pm, so I'll quit about 7pm.

Tomorrow's goal will be to mount the axles, steering, brakes, guages other little stuff. I'll probably work on the body some.

Saturday will be engine transmission day.

Sunday will be whatever else needs to be done like putting a floor in the back of the EB.

[NC_James]

Nice!

I will be in asheville till about 11pm tomorrow 8)

[SamuraiGuyTN]

make sure you post plenty of pictures of the build. :roll:

[Gubni]

Here's some pics. Thanks to Jarret and Ben. We got it cleaned up and most of the rust cut out. The dovetail is mostly done. The axles are mostly ready to go in. We also got the new trans and tcase pulled out of the donor truck. Tomorrow will have the axles mounted with tires and finish the dovetail.

http://www.mustangfarm.com/forum/77eb1.jpg

http://www.mustangfarm.com/forum/77eb2.jpg

http://www.mustangfarm.com/forum/77eb3.jpg

http://www.mustangfarm.com/forum/77eb4.jpg

http://www.mustangfarm.com/forum/77eb5.jpg

http://www.mustangfarm.com/forum/77eb6.jpg

[88yotapickup]

looking good

[Bluegill]

:smokin: EB's rock!

[Gubni]

I plan to order pizza at noon, so if you want some try to be here by 11ish so I know how many to order for.

Probably order some more around 6ish.

[NC_James]

I plan to order pizza at noon, so if you want some try to be here by 11ish so I know how many to order for.

Probably order some more around 6ish.

I wish I could of came by to help. :cry:

[SamuraiGuyTN]

you should steel the name from the Show Trucks and call it Project Crazy Horse. :grin:

[Dino1967]

wished i didnt have to work all weekend i love eb's gonna find lil one soon :wink:

[Gubni]

Special thanks to my Dad and Phil. Today we got the engine running, rear axle mounted, guages installed and some of the wiring sorted out. Tomorrow we will finish the engine install and transmission mount. I will be very happy if we also get the front axle installed, but I'm planning on doing that Monday. So it turned into a 4 day project... :?

http://www.mustangfarm.com/forum/77eb7.jpg

http://www.mustangfarm.com/forum/77eb8.jpg

http://www.mustangfarm.com/forum/77eb9.jpg

[Gubni]

No significant progress was made today.

I realize with all the work to be done it will take longer than time allows.


Thanks to Phil for coming over and helping today.

[NC_James]

Looking good shawn!

[Want2Wheel]

looking good

[Gubni]

Today I ordered the brackets needed for power steering, the clutch pivot on the block, and I'm going to get a new water pump so the alt brackets will bolt up. Next friday I'll try again.

[Jeepguy16]

looking good, motor looks kinda small maye it needs a 460 :grin:

[NC_James]

Looking good man!

[Gubni]

Arghh!

I have a 28oz fly wheel and a 50oz motor and long 50oz harmonic balancer. The motor is a newer fuel injected motor while most of my parts are from the older Bronco.

The harmonic balancer on the newer engines is about half an inch thickner. What this means is my pullys don't line up. So I have to figure this out and pull the clutch and swap the flywheel out for the newer style.

[Thumpszilla]

It will all come together man just don't get frustrated.

[HARDBODY630]

you going to keep it red? or paint it?

[BJack]

Arghh!

I have a 28oz fly wheel and a 50oz motor and long 50oz harmonic balancer. The motor is a newer fuel injected motor while most of my parts are from the older Bronco.

The harmonic balancer on the newer engines is about half an inch thickner. What this means is my pullys don't line up. So I have to figure this out and pull the clutch and swap the flywheel out for the newer style.
I put one together like that one time with the wrong flywheel and it would vibrate your teeth out.

[Gubni]

I don't plan to paint it.

As for balancing, I have a flywheel from a Mustang that should work.

[Want2Wheel]

You need to keep the ballance for the engine. If you need some parts I will be gald to help. I have people.

[Gubni]

Found out my mustang flywheel is 157 tooth and I need 164 tooth. I ordered one from Autozone for $60

[Gubni]

Well after big delays with the motor it's back in again. Friday I will start mouting the transmission and front axle. I love to have some help if anyone wants to stop by.

Here's a list of some of the problems with my free engine. I guess since it was free - can't complain too much.

2 quarts of water in oil pan - poured out.
No oil in engine - got 15 qaurts and three filters for rapid oil changes.
Badly worn timing chain - replaced.
Missing hole in block for clutch linkage - bought bracket.
Valve stud nuts on upside down and one stripped - fixed.
Missing valve cover bolts - replaced.
Old flywheel with new engine unbalanced - bought new flywheel.
Old style clutch won't bolt to new flywheel - bought refurb pressure plate.
Wrong water pump won't allow pullies to line up - bought new one.
Missing pilot bearing in crank - installed.
Missing exhaust manifolds - took off another bronco.
Starter siezed up - got warrantied (duralast).

[Bluegill]

Sounds good Shawn. Wish I wasn't working then, I'd love to come help.

[Gubni]

I got the transmission in today. I need to make a crossmember and transfer case mount. I'm going to try to get the front axle in today also.

[Gubni]

Just got finished bolting on the front axle. I need to make a spring strap and figure out the steering and tracbar lengths. I only worked on it for abou 4 hours. I think two more days should have it drivable.

[Gordon]

Making great progress, Shawn. I gotta take a run over and check it out.

[Gubni]

Got the front axle install finished with steering and tracbar. I will have to clock the pitman arm on the gearbox to correct for the longer draglink. I shortened the tracbar welded it really good, then gusseted it.

I got my bikini top in today.

To do list

1. make crossmember
2. make driveshafts
3. install hood
4. work on wiring some
5. install roll cage
6. install softdoors and rear curtain
7. install steering column
8. install seats
9. hook up and bleed brakes
10. fab some bumpers
11. adjust dovetail some
12. cut out rear wheel wells and install floor
13. install pedals
14. install fan and shroud
15. fab spare tire mount
16. install gas tank

[Gubni]

Here's pics.

http://www.mustangfarm.com/forum/77eb10.jpg

http://www.mustangfarm.com/forum/77eb11.jpg

[Dino1967]

kool great progress

[Gubni]

Got the crossmember and driveshafts mostly taken care of. I need to new ujoints, a yoke, and to drill 3 more holes. I hope to drive it tomorrow.

[Thumpszilla]

Great progress man! Can't wait to see it on the trails.

[Gubni]

Got the crossmember finished and the fan installed. Worked on the wiring, clutch linkage, brake and clutch pedals, installed power steering hose, got the cage in the shop, installed a missing headlight, reworked upper radiator hose, installed electric fuel pump.

Tomorrow I'm going to pull the rear gas tank, clean it and put gas in it. I've got to wire up the fuel pump, install the rear driveshaft, and bleed the brakes. Then installed the steering column, finish the pedals, and put a seat in it and go play in the snow.

[Hilla-GO-Rilla]

You rolling yet?

That things going to be sweeeet :grin:

I took Summit home from JC last night and saw your shop lit-up like the Holiday Inn...somebody's burning the Midnight oil :thumbleft:

[Gubni]

Yeah still working on some of the little stuff. I got most of the brake work done. I got some used lift springs that are worn out and no higher than stock, so I ordered another set. I still need to install the steering column and some more wiring.

[HotRodYJ]

Yeah still working on some of the little stuff. I got most of the brake work done. I got some used lift springs that are worn out and no higher than stock, so I ordered another set. I still need to install the steering column and some more wiring.

Just stretch em back out. :rabbit:

[Gubni]

Yeah still working on some of the little stuff. I got most of the brake work done. I got some used lift springs that are worn out and no higher than stock, so I ordered another set. I still need to install the steering column and some more wiring.

Just stretch em back out. :rabbit:

I seriously thought about that. I could use the cherry picker and some channel on the bottom. I'm just worried about safety or I would.

[pplblazerdude]

Yeah still working on some of the little stuff. I got most of the brake work done. I got some used lift springs that are worn out and no higher than stock, so I ordered another set. I still need to install the steering column and some more wiring.

Just stretch em back out. :rabbit:

I seriously thought about that. I could use the cherry picker and some channel on the bottom. I'm just worried about safety or I would. I dont think it would be a very smart idea to be honest.

[Gubni]

Well, if it could be done safely it would work. I wouldn't be changing the spring rate, just the spacing.

[HotRodYJ]

Actually I was totally kidding. Might be worth a call to Spring Sevice though and see what they might say about it.

[Gubni]

Phase one is almost done. I still have to install the rear driveshaft, seats, and steering column. I think I may attempt to make my own exhaust from junk tail pipes I have lying around. Other than that everything is installed. I still need to do a few oil changes, some more wiring, and bleed the brakes.

I just found some wiring diagrams on the net, so that will help.

I never knew how long it could take to do brakes. I had to install everything from the brake pedals, mastercylinder, proportioning valve, steel lines, rubber lines etc.

Phase two will be pushing the front axle forward a few inches and leveling it some along with working out any bugs. Right now the rear is about 3" higher than the front. I need to decide if I want to raise the front or lower the rear.

Phase three will be installing the cage and rear decking.

[SamuraiGuyTN]

if you put a winch on the front it may lower it just a little. then you can raise the back 2".

[Gubni]

Right now the rear is about 3" higher than the front. I need to decide if I want to raise the front or lower the rear.

if you put a winch on the front it may lower it just a little. then you can raise the back 2".

[-(

[Gubni]

Got it mostly done today. Most all of the wiring got finished. I still need to install the steering column and seat. No big deal there, just makes wiring under the dash easier to get to without it there. I still need to wire up the fuel pump properly and install exhaust. I thought I'd go ahead and start it tonight simply for a fealing of accomplishment. It acted like the battery was low, so I hooked up the charger and set it to 200amp start. Still nothing. I put a socket on the crank and it won't turn over. I took out the starter and used a pry bar on the flywheel and it won't budge. There is something wrong in the transmission or clutch. I will have to pull that apart again...

[Thumpszilla]

Sorry to hear about the setbacks man but it will come together in Gods time.

[Gubni]

The problem is the pressure plate is touching the bell housing. Now I have to figure out if I need to get a different pressure plate or grind the bell housing.

[Gordon]

Shawn, if you can tell me whatcha got now for the pressure plate, I could try to scope out some alternatives tomorrow when I'm back at work. I can pull them out of the boxes and measure heights, etc. I'd be happy to try.

[Gubni]

Once I took a break and went back out I noticed it was hitting on an edge rather than th main clutch body, so a moment with the grinder fixed that. It's back in and turns freely. Now just to put the trans and such back in and start it up. Thanks for the offer. 8)

http://www.mustangfarm.com/forum/clutch1.JPG

http://www.mustangfarm.com/forum/clutch2.JPG

http://www.mustangfarm.com/forum/clutch3.JPG

http://www.mustangfarm.com/forum/clutch4.JPG

http://www.mustangfarm.com/forum/clutch5.JPG

[Gubni]

Well she runs. I will drive it out of the garage tonight. It's not done, but great progress was made.

[Dino1967]

great to hear :!:

[BroncoMike]

He Shawn are you going to work on it any tomorrow morn or afternoon. Actually I could come over any day this week if you are going to be working on it any.

[Gordon]

Well she runs. I will drive it out of the garage tonight. It's not done, but great progress was made.

Cool deal. Gotta ride by and check it out. Glad the clutch deal was minor.

[Gubni]

He Shawn are you going to work on it any tomorrow morn or afternoon. Actually I could come over any day this week if you are going to be working on it any.

I'll be here most of the day tomorrow.

[BroncoMike]

He Shawn are you going to work on it any tomorrow morn or afternoon. Actually I could come over any day this week if you are going to be working on it any.

I'll be here most of the day tomorrow.

What would be a good time to come over. I could be there just about as early as you want.

I'll get up first thing and check the thread in the morning.

[Gubni]

I actually drive it about 2 foot today. Then the coil died. I decided to call it a night.

Mike if you want to be here at 9am that's when I will start.

[Gubni]

Thanks to Mike for his help. We got most of the wiring figured out and drove it to the back field and back today. Everything seemed to work properly.

I still need to install the cage, soft half cab, move the front axle forward and inch or two, level it, wire the turn signals, and hook up the choke.

[Thumpszilla]

Great progress man.

[Gubni]

http://www.mustangfarm.com/forum/77eb1b.JPG

http://www.mustangfarm.com/forum/77eb2b.JPG

http://www.mustangfarm.com/forum/77eb3b.JPG

[Thumpszilla]

Now you have something for those tighter trails. Have you considered dovetailing the front? I have pics of an eb somewhere that is dove tailed front and rear and it looks awsome.

[BroncoMike]

Shawn no thanks needed man, you done most of the work anyways. Sorry I couldn't have stayed and done more. Maybe next time man!

[Bluegill]

Looking good, Shawn! 8) Might want to add bumpers to the list of to-dos :wink: Like Sam said, that EB will be more mountain trail friendly than Grey or Grizzly.

[Gubni]

Yep, need bumpers also.

I don't plan to dovetail the front. The only reason I did (actually Jarret did) the rear is because it was rusted out.

[Want2Wheel]

Looking great

[Hokie_YJ]

Nice tires! :lol:

[Dino1967]

doving the front would take away the bronco look
glad you are not going to do it :!:

[Gubni]

Here's the specs and current todo list

77 early bronco body and frame

77 F-150 Dana 44 Front axle
81 full size bronco 9? rear axle (3500lb)
3.5 gears
31 spline spool in rear
1310 CV and joints front and rear
3? lift blocks

77 F-250 NP435 transmission
77 F-250 NP205 transfer case

302 from EFI vehicle
New electric fuel pump
New timing chain and top end gaskets
Rebuilt ford 4bbl carb
custom Saginaw power steering pump
77 Bronco power steering hose
73 Bronco power steering gear box
86 Bronco flywheel and clutch kit (new)
New starter
New starter relay
New battery
New distributor
New water pump

Winch bumper
Warn 9000 winch
Dove tail rear
35?s glued on 15x8 rims
New exhaust


Todo
Weld rear spring perches better
Redo t-case mount
install 3.5? front lift springs
fix or replace rear springs
floor boards
finish dovetail
rollcage
softcab
move front axle forward 2?
radio
cb
horn
turn signals
spare tire mount
poly rag joint

[Rtaylor]

Do you have the 4 turn steering box or the 6 turn unit. I changed to a 4 turn on mine when I had it rebuilt. It made it a whole lot more fun to drive. I wouldn't do it unless you need to have the box rebuilt though...

[Gubni]

I have the 6 turn. For now that's fine.

[Gubni]

I just want to say thanks to Pitch for coming by and helping get the body straight on the frame. It now sits level and the passenger side tire has some clearance.

Today Pat and I worked on moving the front axle forward 2". We got it all done and ready to weld up and ran out of gas. I got to Northern at 8:05 and told them I'd pay extra and for them to ring it up tomorrow, but they said no way. Tomorrow I'll weld up the new brackets and drive it through my little trails. Big Justin is going to help with replacing the broken rear springs which will also move the rear axle back 2". I think Pitch is going to come by and help me weld in a passenger side floorboard. After all that I may even install the roll cage which will require some more interesting fab work.

[Bluegill]

:smokin: Sounds good man!

[Thumpszilla]

Cool keep us updated.

[Gubni]

Still lots of work to do, but thanks to Pat and Drake it's alot closer. I actually drove it through my trails yesterday.

http://www.mustangfarm.com/forum/ebruns1.JPG

http://www.mustangfarm.com/forum/ebruns2.JPG

http://www.mustangfarm.com/forum/ebruns3.JPG

http://www.mustangfarm.com/forum/ebruns4.JPG

http://www.mustangfarm.com/forum/ebruns5.JPG

[Thumpszilla]

cool man

[Gordon]

Great progress, Shawn. Lookin' good.

[LoOnaTik]

Great progress, Shawn. Lookin' good.

x2 :lol:

[tennbronco]

ya know I hate to burst bubbles but didn't you forget to mention how ya made it through the trail good except for where I had to pull ya off that stubborn log and what ya don't even thank my girl for those good pics ??? LOL looks good shawn can't wait to help ya some more so we can get that rig rollin good and on the trail soon.

[Gubni]

Ahh, man you didn't have to tell them about me gettin stuck. I'll make it next time though. Just have to get used to the steering.

[Gordon]

:lol: :lol: :lol:

[Dino1967]

glad ya got it going