'72 Ford Bronco resto
 

Hi, it's me dne', I still keep my eyes on this forum, RickySnickers suggested in put a build thread, so I'm doing just that;)

On my 59 Chevy, I had bought it back in 2011 and just recently sold it for 17.5 to be able to buy this in poor condition '72 Ford Bronco. My 59, I had taken it as far as I could, or wanted. It had some issues, mainly body and the fella that bought it, I showed him everything so there were no hidden facts that he would have to deal with.

Anyway, I was having difficult time figuring what I'd like to spend the next few years of my life on, something to keep me busy and the Bronco seemed to be a pretty cool ride.

The day we brought it home; just fit on my 14' trailer.
https://i.postimg.cc/1XFJFVH9/72-Ford-bronco3.jpg

It's pretty easy to work on, removal of the body was straight forward. As I've learned, Broncos had problems with rust and I found my fair share of rust I'm going to have to deal with, but parts are available as with most old cars/trucks. I'm using my brothers jeep tires to move it around, the tires which were on it were SHOT.
https://i.postimg.cc/L5ngssVF/Bronco_body_removal2.jpg


This is the original engine, original everything before stripping. Note the front frame horns, omg, somebody put those on and lucky me got to remove all of of it and weld on some used frame horns and lucky they're available!
https://i.postimg.cc/pT0nxjzB/Bronco-body-removal3.jpgThe plans: change out the 3 speed manual for an automatic (c4). All the other classics I have are manual and my husbands left hip is giving him trouble, I'd just like him to be able to drive it when done.

I belong to a Classic Bronco forum, and on that site, a member had a C4 for sale, but he was upgrading his Bronco by means up 80-90k dollars. He had his 302/C4, suspension, tires, front axle(mainly for me was the disc brake upgrade to put on my Dana44), just too many parts to list, all for 4500. Super nice guy to boot!

This is the Bronco of which I bought just about everything he had for sale (this is not my bronco). I have those wheels and they are totally awesome.
https://i.postimg.cc/wBrbCQhH/Bronco_wheels.jpg

Since I bought that guys engine, it has about 19k miles on it, so I built an engine run stand to play with it of which I've already had running on it. It sounds great, all I had to do was pull the intake, valve covers, pan, re-seal, make pretty.
https://i.postimg.cc/Gp2q9HkX/Tims_stuff5.jpg



https://i.postimg.cc/J0wqTxSF/Tims_stuff4.jpg

As said~ I had a little fun fabbing up this engine run stand
https://i.postimg.cc/JhBhy8W6/Engine...nd_gauges1.jpg

My first Ford True-track 3.50 chunk setup;)
https://i.postimg.cc/Jnm4T40s/Ford_9_setup3.jpg

Please forgive me, I'm kind of out of order, but this is the frame, I had to replace all frame horn ends and do some other repair work, but it turned out great!
https://i.postimg.cc/YSTYNf8N/Bronco-frame-paint4.jpg

https://i.postimg.cc/SR9h2qR7/Bronco...-completed.jpg

Ok, I'm going to leave it as this and ad onto it, we've got to get ready for kids/grandkids coming over for Thanksgiving;)

It's nice to be on this forum again~ lot's of great people that I remember here;)
dne' ;)

Re: '72 Ford Bronco resto
 

This is great! Thanks for sharing.

Re: '72 Ford Bronco resto
 

watching this one!!

Looking great so far.

Re: '72 Ford Bronco resto
 

That looks great with the new tires and wheels

Re: '72 Ford Bronco resto
 

I'm gonna watch this one - with some jealous eyes.

Re: '72 Ford Bronco resto
 

When I got the Bronco, I immediately started thinking about having uncut fenders. My front fenders and grill were shot, so it was a matter of shopping for new or used stuff.

https://i.postimg.cc/dQZWpgKz/72-Ford-Bronco1.jpg

A fella on the other side of Houston put up for sale and set of uncut used but nice fenders and a new grill for 500 bucks. So, I bought those and now I had to figure out what to do about the rear fenders.

A fella in Houston had these cut outs and offered them to me thinking I could weld them in and have "uncut fenders".
https://i.postimg.cc/TY7HYMkL/Bronco_fenders3.jpg

But after the blasting process, I found my rear lower fenders were shot which led me to options.
https://i.postimg.cc/zXLYrCWW/Bronco_blasted3.jpg

After painstakingly removal of the lower panels, I found that a company or many companies make fender panels with the higher arch to allow for larger wheels.
https://i.postimg.cc/h4yJBdhq/Bronco_lower_panelb.jpg

So, I got them last week and was able to mock them up and I'm thrilled that I'll have a Bronco with the uncut look!
https://i.postimg.cc/hjHqbWbp/Bronco_bed_panels1.jpg

Here I was just re-installing the old tub system just to see what I was going t to have~ I'll have the correct rear lower panels and feel it's going to look very very nice!~!
https://i.postimg.cc/MZgLXKHM/Bronco-stance.jpg

of course this will be gone, but just looking to see what the stance is going to be;)
https://i.postimg.cc/Y01rmLz8/Bronco-tub5.jpg
dne' ;)

a bunch of kids are here, so I got to go do the grand parent thing! I'll be back!!

Re: '72 Ford Bronco resto
 

Stance looks good! Nice work. Looking forward to watching.

Re: '72 Ford Bronco resto
 

First just like to thank you guys for being here with me and giving encouragement~ I for sure don't know everything, but have gained a lot of experience over the years!!

Overall, this is kind of how my Bronco should sit, maybe not quite this high, and color is definietly up in the air;)
https://i.postimg.cc/J7JbR1kz/left-flared-quarter-f.jpg

Re: '72 Ford Bronco resto
 

Now that’s a project ! Coming along nicely .

BTW put a link in your sig. to the build .

Have a great Thanksgiving !

Re: '72 Ford Bronco resto
 

Thank you Glen! and all my Routy friends!! ;)

The kids went to visit some of their friends this afternoon, so I had some time to sneak out to the garage;)
I know this isn't an exciting entry, but I had just enough time to remove the support from the Bed floor~ I could have bought a new one, but I do try to "save" a little money when I can. A new one is only 40 bucks, but shipping is about 20, then Tax. So, I did save a little;)

https://i.postimg.cc/NfYq4kq7/Bronco-bedb.jpg

https://i.postimg.cc/sf5C708g/Bronco-bed1.jpg

https://i.postimg.cc/650s14Bs/Bronco-bed.jpg

I love the holidays, but I love being in my garage!!! There's always something to do!
dne'

Re: '72 Ford Bronco resto
 

When I bought the poor thing, looking at the bumpers, my thoughts initially were, I'll just unbolt what is on there and repair whatever. haha

I guess in this broncos life, people in the past get these great ideas to make the truck even truckier!
The front bumper horny things were from something else to mount a large ugly bumper.
https://i.postimg.cc/vmp3dcFk/Bronco_frame2.jpg

https://i.postimg.cc/m2YHHZkG/Bronco...ame-horns3.jpg

The 200lb rear bumper was welded on
https://i.postimg.cc/L5ngssVF/Bronco-body-removal2.jpg

Luckily, frame end repairs are available, but the front ones, I forget which company, but they have a bunch of old frames and I bought the fronts for about 300bucks. Much cheaper than buying a new frame.
https://i.postimg.cc/vZGmGf9V/Bronco_frame_specs2.jpg

Getting the rear horns on was "easy", but the fronts were a little more challenging and there is a site which shows the "datum line" where things are supposed to line up. I used my laser beam to show me where the front pads for the body are supposed to go and a lot of other measuring before welding in place.
https://i.postimg.cc/bN14B2BD/Bronco-frame-specs6.jpg

I have already removed the rusty front wheel wells which also had the front body mounts and when the day comes to put it all together, I'll have to put the entire body back on the frame to make everything capeesh before tacking things into place.
https://i.postimg.cc/HxJgys5r/Bronco_engine_bayb.jpg


Gary's bugging me to watch TV, so guess I'll have to say Goodnight;)
dne'

Re: '72 Ford Bronco resto
 

Man, I thought our stuff was rusty, can you say Swiss cheese......

Great work so far , I'll watch for sure

Luckily the price of these things has sky rocketed

Your shop is awesome

Re: '72 Ford Bronco resto
 

Yes Jim, Swiss Cheese! very sad. I was seriously thinking to buy a new tub, but 10k +shipping, but I have to see what I can do, I think I can bring it back ok;)

https://i.postimg.cc/3xt9cb9Y/bronco_tub.webp

Re: '72 Ford Bronco resto
 

Great project!

Re: '72 Ford Bronco resto
 

Thank you Yukon Jack! As bad as the project is, it feels good to be able to bring it back to life for another go in its life, or my life;)


Backing up a bit~ Whomsoever owned it, must have gone mudding in really deep mud and probably didn't give a darn about the poor Bronco:(

I think it's human nature of folks like us here on this forum and all forums to have an instinct to save these old machines, regardless of what shape they're in.


My first goal upon getting it was to clean it! omg, it was seriously packed with mud! During pressure washing, I too became covered in mud and grime~ I was obsessed with making it clean!!! grrrrr
https://i.postimg.cc/hvcWp2Wf/Bronco-maxjax.jpg

Pictures speak for themselves, the Bronco had no brakes despite a new master cylinder. But there were no brake lines on the rear axle AT ALL! Not that I need brakes at this time as it will receive all new brakes, lines, etc.
https://i.postimg.cc/SNhj5yNX/Bronco-brakes2.jpg

Nothing like undercoating to hide bad things:(
https://i.postimg.cc/26Lmz8DN/Bronco-bed.jpg

The fella that I bought all those parts from, his Dana 30 had the disc brake upgrade, but I kept my Dana44 ,but the Disc brakes fit my Dana44, so saved a little money there.
https://i.postimg.cc/PrZRxT6Z/Bronco...kes_paint2.jpg

https://i.postimg.cc/63MvTZPK/Bronco-rear-brakes1.jpg

I bought this Yukon axle set, it was on Amazon for 159.oo, but must have been a mistake as it retails for right at 400, so, a little money saved on someone's mistake. Of course I had to have the new bearings pressed on.
https://i.postimg.cc/6qS4WGzq/Yukon_axles2.jpg

So, you're learning a little more history of this poor thing;)
dne' ;)

Re: '72 Ford Bronco resto
 

Nice attention to detail, what you have done so far looks amazing

Keep it up and you will have a beautiful truck

Now I need to go back and look at your other truck build

Re: '72 Ford Bronco resto
 

Thank you Jim!! I do try!!
dne'

Re: '72 Ford Bronco resto
 

Well my dearies, kids are gone, I love em, but nice that we have our house back. Sadly kids spend most of their time on either their cell phone, TV, or now~ Virtual reality games! :crazy:

I had just enough energy to whittle this corner off and kind of see how the new piece looks. I'm not welding anything in place, if fact I need to order some self-tapping screws to hold things in place, I certainly don't have enough welding vise-grips!
This first pic is from a few weeks ago test fitting the lower quarter panel.

https://i.postimg.cc/L41S4527/Bronco_bed_panels.jpg

Got a bunch of parts in, so, I have plenty to do this week!! Can't wait!!
https://i.postimg.cc/K88ybBb2/Bronco_door_jama.jpg

https://i.postimg.cc/MZ1wmz5h/Bronco_door_jam.jpg

I hope everyone had a great ThanksGiving! Now, back to work!! lol
dne'

Re: '72 Ford Bronco resto
 

Have you considered clecos hold well and come off faster then screws. Actually started to use magnets, super. strong, got them from Eastwood

https://live.staticflickr.com/65535/...42423f5d_c.jpg16380607208285020500543644742208 by [url=https://www.flickr.com/photos/97391199@N06

Re: '72 Ford Bronco resto
 

Hey, Jim, kind of funny, I have some clecos in my tool box, but never have used them. I'll have to look into the magnets.
thanks;)
dne'

Re: '72 Ford Bronco resto
 

My brother in law worked for Boeing, and got me hooked on clecos, he was a fanatic of neatness, so he made a sheet metal holder for them, easy to find and no more rolling around in the tool box

https://live.staticflickr.com/65535/...d217185c_c.jpg16381941465132985574264722585348 by [url=https://www.flickr.com/photos/97391199@N06

Re: '72 Ford Bronco resto
 

I'm subscribed to watch. Looking good!

Re: '72 Ford Bronco resto
 

Thank you Jim and Ol Blue;)

I have to say, I'm a little overwhelmed on this Bronco body, however, I'll get it done. I kind of wish I could start over, mainly to go over buying parts. meh


Yesterday, I test fitted the drivers side parts, just using some self tapping screws, cause that's what I have.


https://i.postimg.cc/Nj8MhbGj/Bronco-doorsa.jpg

Also got this part mocked in place. Already did the drivers side. These are "easy".
https://i.postimg.cc/Gpqmt2y0/Bronco...nger-door5.jpg

The drivers side is holding things together, or just enough to take apart the passengers side.
https://i.postimg.cc/MK2Mhn0t/Bronco...nger-door4.jpg

I need to remove the engine from the frame, have no idea of why I did that so soon! So, today I'll do that, remove the engine, put it back on the engine stand. Clear a path to bring the frame assembly cause I really need to start putting the body on the frame for alignment purposes, doors, etc.

so, that's my plan, or so;)
dne' ;)

Re: '72 Ford Bronco resto
 

Hi Gang! Holidays really slow progress; happens every year :lol:

I've since welded this into place, I have some more patches to do, but it's looking ok.
https://i.postimg.cc/FzxNVtxq/Bronco-floor.jpg

I finally decided to put the cab on the frame, just was having problems supporting the cab/bed. I just need to weld in the floor support as there isn't one on the passenger side, that's where my crane is holding up that side.
https://i.postimg.cc/ZqYJDNps/Bronco_body_on_frame.jpg

Just a glamour shot of the right front fender;)
https://i.postimg.cc/7YmqCkhJ/Bronco-body-on-frameb.jpg

Engine compartment less engine, inner fenders; there's no body supports in the very front yet; need to put the whole thing together to see how it aligns.
https://i.postimg.cc/Y2NrHgw3/Bronco-body-on-framed.jpg

I'll get to this bed someday, focusing on the cab for now.
https://i.postimg.cc/Wb22b3NP/Bronco-body-on-framec.jpg

Others: on Fbmarket place, I found a new drivers door shell (Dyna) for 150;)

I'm in no hurry, having a good time getting out there, even if to sit in a lawn chair and enjoy the moment;)

Re: '72 Ford Bronco resto
 

https://live.staticflickr.com/65535/...f819b1f4_c.jpg16392671711057252775087646200109 by [url=https://www.flickr.com/photos/97391199@N06

Found a really useful tool its for getting the sheet metal apart, at the factory seam, after you drill the spot welds. I had to buy 3, so I'd be happy to send 1 your way

Seem to be well made, and should stop ripping sheet metal

Trucks looking much better

Re: '72 Ford Bronco resto
 

Hey Jim, those separators look really neat! I think I only have about 20 welds left to drill. I've been using my old wood chisel which has metal all the way through and it works well. I thank you for the offer, but I'm ok;) I hope I never have to do such an intensive body restoration again!

Amazing things about spot welds, it such a good feeling when you drill them right and they just fall apart(rare);)

Too cold for me today to do anything in the shop, so I'll take this day to spend with my husband;)
dne'

[quote=jaros44sr;9006116]https://live.staticflickr.com/65535/...f819b1f4_c.jpg16392671711057252775087646200109 by [url=https://www.flickr.com/photos/97391199@N06

Found a really useful tool its for getting the sheet metal apart, at the factory seam, after you drill the spot welds. I had to buy 3, so I'd be happy to send 1 your way

Seem to be well made, and should stop ripping sheet metal

Trucks looking much better[/quote]

Re: '72 Ford Bronco resto
 

Hi gang! the holidays really throw off progress, but a few days ago I decided to put the Bronco on my 4-post lift, also put the hood on for alignment purposes, though it looks good, I'm having a devil of a time with the drivers side(new door post, striker post, door, kick panel, etc). I hope to make some progress on it, but I haven't even welded anything together, just screws.

https://i.postimg.cc/KvzRvXg9/Bronco_on_liftb.jpg

https://i.postimg.cc/4y8ybPjb/Bronco_on_lift.jpg

I do have the bed in place and that's giving me a fit! Seems like nothing is lining up:(
https://i.postimg.cc/HW3rgWjc/Bronco_on_lifta.jpg

I hope tomorrow I can have a full day to get something done;)
dne' ;)

Re: '72 Ford Bronco resto
 

Have patience, you'll get it! :metal:

Re: '72 Ford Bronco resto
 

lol, I know I know;) I'm ready to get back at it, but 41 degrees doesn't work for me:(

Re: '72 Ford Bronco resto
 

Why do you have a picture of a TR6 on your wall?

Re: '72 Ford Bronco resto
 

Jim, that's a good question and thank you for asking! A while back I had the hots to do a TR6 ~

Lucky me, got to re-restore my '71 TR6 after Harvey. It was only half flooded going by the lines on my TR, you can just make out the water line.
https://i.postimg.cc/MTcLmPD0/garage-flood.jpg

https://i.postimg.cc/fbgZxxwH/TRmx-2019.jpg

https://i.postimg.cc/jjtV6361/71-Triumph-TR6a.jpg

I installed a Miata engine with a 5 speed transmission;) it's a hoot to drive!!
https://i.postimg.cc/MH1S2N14/TRmx-2019b.jpg
dne' ;)

Re: '72 Ford Bronco resto
 

Wow, you have some impressive skills :)

Re: '72 Ford Bronco resto
 

Thank you Ricky! It's nice to hear someone say that now and then, but I do run into problems where I don't mind asking for help/advice, like this Bronco is taxing my "skills"! ;)

Re: '72 Ford Bronco resto
 

Nice tr6, even a factory metal hardtop, and no hideous bumper guards

In my 20s, I restored English sports cars, triumphs, morgans, mgs, Austin healeys, and the like....

My daily driver was a tr6, loved it

Bronco, coming along, but understand cold workshop, I put a separate zone in my boiler, so I could have a thermostat in my workplace

Keep going, you're doing great work

Re: '72 Ford Bronco resto
 

Closing in on 2 months with no updates. What gives??? :)

Re: '72 Ford Bronco resto
 

omg, let's catch up!! where did two months go!!!

Here was just more test fitting/trimming to make these darned floor pans fit.
https://i.postimg.cc/NFPgWVNL/Bronco_floor_pans.jpg


https://i.postimg.cc/Vs7LrrY1/Bronco_floor_pans1.jpg

I found that the aftermarket door post(A pillar) are not made to perfection and caused me a lot of grief getting the door to fit, but I finally came to a compromise and it should be ok.
https://i.postimg.cc/d1PbFtSx/Bronco_bedm.jpg

Here I was/am satisfyed with that darned body line. That's an after market door skin, my first and it actually came out pretty good;)
https://i.postimg.cc/pLybYSFq/Bronco_body_linesb.jpg


Here, I'm just saying HI! The bed is connected and welded into place, no going back now.
https://i.postimg.cc/Pq8g08KD/Bronco_mea.jpg

I kind of got these out of order, but you'll figure it out;) I broke down and bought a new windshield frame (500bucks). This poor bronco was a rust bucket:(
https://i.postimg.cc/pVJdv2P0/Bronco...eld_frame2.jpg

I was having difficulty fitting this new grill to the fenders, especially while on the body. I found it's much easier to put it all together and mount as a single unit, but I had to put it on, take it off a few times.
https://i.postimg.cc/GtD4gBpj/Bronco...nal_lampsb.jpg

Why they had to use a piano hinge is beyond me!
https://i.postimg.cc/hjFGDvJY/Bronco...eld_frame6.jpg

Not long ago, couple weeks, I disassembled the seats which were in the Bronco, they're very rusty. I'll have em sandblasted, but look for options regarding replacement seats.
https://i.postimg.cc/BQkfmLGy/Bronco_seat_frames.jpg

Just a couple days ago, after being ok with the body lines and fitment, it was time to remove the body. I think this is how I'll be painting this Bronco. The lift goes high enough to get underneath and adjustable to paint everywhere else~ so that will be good!
https://i.postimg.cc/cCJGbfCq/Bronco_on_Maxjax.jpg

Looks like a Bronco??;)
https://i.postimg.cc/VLdc992n/Bronco_with_grill.jpg

The Maxjax is such a fantastic tool! I lifted the body off the frame and that's where the body will be for the next however long.
https://i.postimg.cc/cCJGbfCq/Bronco_on_Maxjax.jpg

I was informed on the Bronco forum that in order to have aftermarket AC, I need to modify the cowl on the passenger side. I was kind of happy about it as I didn't know what I was going to do about it.
https://classicbroncos.com/forums/th...5#post-3420643
https://i.postimg.cc/ZRc0gxwc/Bronco-cowlz.jpg

I'm making the top removable as I was told to to have access to the top of the evaporator case(which I havent' bought yet)
https://i.postimg.cc/zB5V0cFv/Bronco-cowlb.jpg

Though not finished, this is how it will be. Just need to finish this up today I hope;)
https://i.postimg.cc/LsjJkpfG/Bronco-cowli.jpg

I apologize for not keeping up~ I promise to better!
dne' ;)

Re: '72 Ford Bronco resto
 

A little on the bed. I only save a couple original pieces, you know, trying to "save money"lol

https://i.postimg.cc/26Lmz8DN/Bronco-bed.jpg

Here I have it hanging by my crane, no way to really support from underneath, very flimsy.
https://i.postimg.cc/GhJk46YC/Bronco-beda.jpg

These new higher arched lower quarter panels are so nice! I Think they will look much better than someone who "cut" their fenders to allow for bigger wheels.
https://i.postimg.cc/hjHqbWbp/Bronco-bed-panels1.jpg

Since I work alone, I have to rely on lifting tools, like my Little MuleII, actually just a hoyer lift, but works great as a second hand. Here just seeing how the bed floor was going to fit.
https://i.postimg.cc/901BZqY3/Bronco-bede.jpg

I don't think in the picture it is totally welded in place, but it is now;)
https://i.postimg.cc/d1PbFtSx/Bronco-bedm.jpg

ok, a nice day, I'll be back hopefully with some new pics!!! bear with me;)
dne'

Re: '72 Ford Bronco resto
 

Wow, that's awesome. Thanks!

Re: '72 Ford Bronco resto
 

Nice, you're doing great.

Re: '72 Ford Bronco resto
 

Hi D’nee
Gee you really pick the rough one’s to start with and then make them great again.

Do you have any pictures of the rebuild of the poor wet Mustang redo ?

Keep up the great work !