Early Bronco Build

[Steve]

A very major rebuild of the EB has begun. It's gonna be a lot of work but it'll be worth it when it's done. Plans for it include:

- Narrow the entire tub 8" to match the front
- Front Kingpin HP D60
- Rear shaved 14 Bolt
- F&R coilovers, four link rear, custom radius arms on front
- New cage
- New seats and harnesses
- Fuel cell
- Notch frame and clock Atlas up so I'll have a flat belly pan
- Full hydro steering
- New bumpers F&R
- Stretch wheelbase almost 12"
- All new wiring
- Straighten everything and repaint

Plan is to have it riding on 40" tires with same height it's at now on 36's. Gotta be done by April at the latest. Some pics today:

Before:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4465.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4464.jpg


Cage and interior removed:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4477.jpg


Some of the major parts collected so far:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4476.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4475.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4474.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4473.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4469.jpg


If anyone gets exceptionally bored this winter, stop by and I'll fix that problem. :D

[birddog59]

Cool! Will look forward to the progress reports.:beer: Sweet Hood!

[jimminyC]

Nice Dents!

[TracYJ]

I figured Justin would have jumped on this already, but shouldn't this be in the Tech section? :flipoff2:

Seriously, can't wait to see the final project, I'm sure it will turn out awesome. You do really good work Steve...now if I could only afford to have you work on my rig.

[Hayes]

I figured Justin would have jumped on this already, but shouldn't this be in the Tech section? :flipoff2:

Seriously, can't wait to see the final project, I'm sure it will turn out awesome. You do really good work Steve...now if I could only afford to have you work on my rig.

x2:D

[SUPERGILDO43]

sweet steve!

hey, wherede you get those sway a ways?

[cheepin]

How are you planning on doing the narrowing?4" each side,like Gremilion?Or all 8 down the center?

[Steve]

sweet steve!

hey, wherede you get those sway a ways?

Wally, who got them from Crazy Ed. Probably where I'll buy the other two when I need them.


How are you planning on doing the narrowing?4" each side,like Gremilion?Or all 8 down the center?

4" out of each side. Taking 8" down the center would be a huge PITA on the firewall, and the tunnel would disappear, which wouldn't work. Gonna narrow the tailgate too and make it so it still works.

[ColoradoXJ]

i think you should just sell it and build up an xj instead... WAY cooler :flipoff2:
































just kidding... i'll be excited to watch (and maybe see up close when i'm in GJ in 2 weeks...)

[Colin]

Very cool Steve, should be a great build.

Does C&S have a shop yet or...?

Are you extending the wb 12" solely in the back, dovetail?

[Clint]

Very cool Steve, should be a great build.

Does C&S have a shop yet or...?

Are you extending the wb 12" solely in the back, dovetail?


Still working out of my shop (22x40 shop). Steves project is being done at his place as of this point due to the fact I will have two rigs in the shop very shortly. We ARE looking for some shop space, but with the oil and gas craziness going on in GJ, shop space is at a premium. Steve is going to be calling about a place I found, hopefully something works out there, but it really hasnt been too bad working out of my place, except that I dont ever get away from it with all the work being right outside my door :D And it would be really nice to have a lift.

[clemsonkrawler]

My shop will support a lift with the 15' ceilings.

Dont worry Tracy... You will be taken care of. :massey:

[Steve]

Are you extending the wb 12" solely in the back, dovetail?

No dovetail since I'm going to narrow the entire tub and I've already narrowed the front. Going to pull the front axle forward a couple of inches and move the rear back 10 inches or so.

And yeah, shop space would be nice, but it's hard to come by here in town and expensive when you do find some. C&S has three major rig builds this winter; two in Clint's shop and my EB in mine. Gonna be a busy winter. :)

[clemsonkrawler]

Dont forget the 3 minor builds at my place.:) Its gonna be a fun white season.

C&S winter build sheet:

YJ - f&r 4 links/coilovers, cage, axles, fuel cell, etc
Fj40 - Resto-mod
Steves EB - you already know

YJ - custom front 60
FJ Cruiser - Racerunner 3.5" lift
ZJ - 3.5" short arm, sliders, bumpers

plus: fix the frame on the YJ and build a track bar and rear bumper/tire carrier for my Tahoe.

[Steve]

Dont forget the 3 minor builds at my place.:) Its gonna be a fun white season.

And a fun spring next year testing all of the new & rebuilt rigs. :bounce4:

[birddog59]

So this thread went from general to pro shop? Any special reason? Will look forward to the build threads and testing!

[clemsonkrawler]

And a fun spring next year testing all of the new & rebuilt rigs. :bounce4:

Hahahaha... theres gonna be a LOT of fresh paint in billings come april.

[Steve]

More teardown today.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4479.jpg


The tub has had carpet glued in since I've owned it. Here's some of what I've found after taking it out:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4483.jpg

This one had an old license plate glued over it with silicone: :rolleyes:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4484.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4485.jpg


Guess I'll order new floor pans. Since I'm narrowing it it's not a big deal, and will make some of the narrowing work easier since I'll be working with new clean metal.

[clemsonkrawler]

dont ya just hate when removing involves 'uncovering'??

[Steve]

dont ya just hate when removing involves 'uncovering'??

The tub is 40 years old. :shrug:

Fortunately I can get all new floorpans and other sheet metal parts at decent prices. :thumbsup:

[BURNTFISH]

That looks like mine.

[ColoradoXJ]

OMG... you started pulling your "EB" apart and found a scout!!!

[bluexj]

Looks good. Will be a fun build and even more fun when done. Sorry I did not relize that was you tonight. Did not know you got a new mustang. Looks good. I was looking at a Bullit edition the other day but decided that it would look funny towing a 4runner around next year.

[Steve]

OMG... you started pulling your "EB" apart and found a scout!!!

:laughing:


Sorry I did not relize that was you tonight. Did not know you got a new mustang. Looks good. I was looking at a Bullit edition the other day but decided that it would look funny towing a 4runner around next year.

Not mine, Kathy's. I get to drive it occasionally. ;)

[SUPERGILDO43]

Wally, who got them from Crazy Ed. Probably where I'll buy the other two when I need them.



nope, those were mine, I knew the grease marks looked familiar!

[Wally]

Steve you're going about this all wrong, you really need to throw in a V6, a high dollar PSC Steering box and a Scout 44 up front :lolly:

Looks good, can't wait to see the progress on this one :drool:

[Steve]

It already has a high dollar PSC steering box - which will be for sale soon. ;)

Just ordered new floor pans, both rear quarters and wheel tubs.

[Mike Boyle]

Dont forget the 3 minor builds at my place.:) Its gonna be a fun white season.

C&S winter build sheet:

YJ - f&r 4 links/coilovers, cage, axles, fuel cell, etc
Fj40 - Resto-mod
Steves EB - you already know

YJ - custom front 60
FJ Cruiser - Racerunner 3.5" lift
ZJ - 3.5" short arm, sliders, bumpers

plus: fix the frame on the YJ and build a track bar and rear bumper/tire carrier for my Tahoe.

Hey, there might be a few minor jobs on a Toyota as well (as soon as I decide which one I'm goin to buy)

[clemsonkrawler]

pickup or 4 runner??

[toyin]

I really like the EB from what i saw of it. I can't wait to see what it looks like after the rebuild. The YJ you did for your kids was awesome, this should be way cooler:beer: Good to hear you guys are staying busy, I may be giving you guys a call for a cage in my 85 later this spring. :beer:

[IoN6]

So this thread went from general to pro shop? Any special reason? Will look forward to the build threads and testing!

Silly commoner, tis because they are pro. :shrug:

[1sicbronconut]

Nice Dents!

Orange Bronco's attract the rocks for some reason:D

[Snotty]

Nice feeling to know you can afford new parts and not have to junk yard source everything on a college student budget, isn't Steve. Interesting that some people fixate on me and masturbate over my threads like they do.

Anyway...

Would like to discuss and watch what you do with your "family" cage and see how we may be able to incorporate some ideas to get a family cage in my Jeepster.

[Colin]

on a college student budget

I take offense to that, I'd love to have the huge budget you have :flipoff2:

[clemsonkrawler]

on a college student budget

I built F+R 60s while in college... waiting tables at a fawkin Cracker Barrel 5 nights a week. Its all in how bad ya want it.

[Snotty]

I built F+R 60s while in college... waiting tables at a fawkin Cracker Barrel 5 nights a week. Its all in how bad ya want it.

I built my 1969 Coronet 440 in college as well. And I am building my current Jeepster with a family. I know budgets all to well. ANd in my case, mine is already tanked. lol

Which is why I am very interested in Steve's thread here. How to do things right, manage a budget for it and still use new and refurbed parts as appropriate.

Steering and brakes aren't areas where I think used parts are appropriate, unless you can't afford them or you aren't concerned about the safety of your passengers and other people sharing the road.

I doubt that C&S is going to cut any safety corners here.

[Wally]

Nice feeling to know you can afford new parts and not have to junk yard source everything on a college student budget, isn't Steve. Interesting that some people fixate on me and masturbate over my threads like they do.


Not speaking for steve, but i KNOW the front and rear axles are "junkyard" sourced....just like yours :shrug: only steve has lots of experience himself AND is willing to take the advice of others with experience, hence the HP front 60 and 35 spline 60 rear vs say something like a scout 44 front where he'll have to pay someone to turn and rotate the knuckles, and completely replace the outters just to make it streetable and comperable to a junkyard waggy 44 :laughing:

Looking forward to the link design steve, i think i spent more time total trying to figure out how in the hell to get the triangulated links front and rear while clearing the driveline and keeping it low, than i have on actual fabrication of the entire rig up to this point....good thing i have lots of beer in the fridge help my buddies and i "think" about the desing :D The more people you can get in your garage to help you "think" about the link design the better :thumbsup: i've been able to build on my ideas based on some really good input from Bluexj, jimminyC, clemsonkrawler, clint, sound_man and many others that have stopped by and given me their $.02

[CSP]

vs say something like a scout 44 front where he'll have to pay someone to turn and rotate the knuckles, and completely replace the outters just to make it streetable and comperable to a junkyard waggy 44

Just an FYI, Snotty has a Waggy 44, not a Scout. Seriously, you don't know all there is to know so stop ragging on him, especially on other people's threads. It's getting old.

[Steve]

II doubt that C&S is going to cut any safety corners here.

Nope, absolutely not. My wife and grandsons will be riding in it, and as you know I don't wheel only easy trails. Occupant safety on extreme trails is at the top of the build list for everything.

As for a budget, yeah it's nice to not worry much about it, but that's because I'm friggen old and done raising kids. :D That said, I did get "junkyard" D60 axles instead of just phoning Dynatrac with a credit card number. I'm also fortunate in that I've already sold over $1,000 in parts off the EB and still have another couple of thousand dollars worth of stuff to sell, so at least part of the build is offset by that.

I won't build anything unsafe for anyone, but I do realize that everybody is different and likes different things. That's why I won't brand bash or badmouth someone for their choice of axles, motor, or anything else.

On topic, a whole bunch of boxes with new sheet metal body parts should arrive before the weekend, so I'll be in the garage this weekend narrowing the tub. :thumbsup:

[clemsonkrawler]

Safety in the form of a cage, seats and harnesses is one place NO ONE should skimp. My full cage, corbeaus, and 4pt harnesses were the FIRST mod ever done to my YJ. The rest of the rig was bone stock still. BTW, Yes, it looked funny.

Keep up the progress steve. Ill be back in about 23 days to lend a hand. Just dont forget to not work on it Nov 1st so you can come to the party!!(more to come on this)

[Snotty]

I guess I should clarify my Junkyard sourcing, since seem to have missed the point.

Do I have junkyard axles? yes, but they are going to be rebuilt. Do I have a junkyard steering box? No... That is a safety item and one that I don't feel should ever be junkyards sourced and installed.

IMHO, and that is my opinion, brakes and steering are areas where I won't put unknown aged/abused parts on my Jeepster. Do what you with your own junk... But the lives of my wife and kiddo are worth the cost of a steering box.

There is a guy on CL that was selling a used cage for a Jeepster. Yeah... Not in my Jeepster...

Steve, just make sure you have enough time to build the cage for my Jeepster! :D

[MountainJeep]

major overhaul!!!

Hey, maybe we can wheel together Summer 09!

[ColoradoXJ]

Safety in the form of a cage, seats and harnesses is one place NO ONE should skimp. My full cage, corbeaus, and 4pt harnesses were the FIRST mod ever done to my YJ. The rest of the rig was bone stock still. BTW, Yes, it looked funny.



my cage is getting finished up today. hopefully get some harness seats before the end of winter... after seeing what can happen to these xj's after a not-all-that hard flop, i wanted something to save my a$$.


steve, are you gonna be around mon/tues? i'd like to swing by and see this in person if that's cool :thumbsup:

[Steve]

steve, are you gonna be around mon/tues? i'd like to swing by and see this in person if that's cool :thumbsup:

Should be around. I think you have my cell #, give me a call before stopping by to make sure I'm there. If you need the # shoot me a PM.

[ColoradoXJ]

Should be around. I think you have my cell #, give me a call before stopping by to make sure I'm there. If you need the # shoot me a PM.

i have your number. it's programed into my "anti-drunk dialing" phone program :P

see you monday.

[Clint]

i have your number. it's programed into my "anti-drunk dialing" phone program :P

see you monday.


Thats no fun.

[ColoradoXJ]

maybe not, but it keeps me from getting the ban stick :D

[Colin]

^^^bahaha.



"Steve! its JUSTIN!!!



Can I drive the STANG? pretty PLEASE?"






:banhammer/

[Jeepster-Matt]

There is a guy on CL that was selling a used cage for a Jeepster. Yeah... Not in my Jeepster...




That was me... And no, it didnt go in your Jeepster;)

[Snotty]

That was me... And no, it didnt go in your Jeepster;)

That was you? lol...

[Steve]

More disassembly. Almost time to cut the tub apart to narrow it.

More Scout metal in the driver's side floor pan. Fortunately the rest of the tub is in real good shape. Should have new floor pans this week.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4488.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4490.jpg


40 years of wiring. Yeah, the whole rig's getting a new harness.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4494.jpg


Empty tub:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4495.jpg


Leaving the motor in the frame. Still have to remove the front axle and suspension.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4492.jpg

[bsaunder]

looks like fun - the last rebuild (that I'm still finishing) way new floor boards, front and rear posts on both sides, kick panels, transmission tunnel, windshield frame, and lots of patches on the bulkhead. Along with an entirely new wiring harness for the full bronco.

Good thing you have autobody experience (ok, that might be understating it)- I had to learn a lot by trail and error, which made it take much longer than needed.

[Colin]

Holy crap, its looks like if your foot slipped off the ebrake you'd go right though the floorboard!

You kick the stang outta the garage?

[Steve]

You kick the stang outta the garage?

Nope, I get half, Kathy gets half for the 'Stang. ;)

[Leon Phelps]

More disassembly. Almost time to cut the tub apart to narrow it.

More Scout metal in the driver's side floor pan. Fortunately the rest of the tub is in real good shape. Should have new floor pans this week.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4488.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4490.jpg


40 years of wiring. Yeah, the whole rig's getting a new harness.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4494.jpg


Empty tub:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4495.jpg


Leaving the motor in the frame. Still have to remove the front axle and suspension.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4492.jpg

And I thought my fleet of ghetto blaster EB's had some floor board rust.....

Looks good. :thumbsup:

[74BuckinBronc]

Everybody loves an EB build.
:popcorn: :bbq:

interested in seeing your ideas for getting the Atlas flat.

J.D.

[89minitruck]

Holy Rust Batman....

[rokcrwlrtj]

As clean as the bronco was when I was out there visiting Justin in March I cant wait to see how it comes together.



What happened to that day in billings when you told me 40's were cheating:P?

[cwkelle]

all clint got was a new bumper for his rig....what gives?:D


jk

[Steve]

What happened to that day in billings when you told me 40's were cheating:P?

I decided to cheat. :D

All new sheet metal arrived yesterday; floor pans, wheel tubs and both rear quarters. Won't make any progress for a bit since I'm heading up elk hunting Friday for a week.

[Swat]

Hey, good luck with it!


What's that round thing that sits high on the engine?

[Leon Phelps]

Hey, good luck with it!


What's that round thing that sits high on the engine?

I'm gonna go with a functional scoop.

[Steve]

I'm gonna go with a functional scoop.

It's an air cleaner. :shrug:

I suspect Swat's question has to do with his affinity for superchargers - but not the blown engines that follow. :D

[Swat]

It's an air cleaner. :shrug:

I suspect Swat's question has to do with his affinity for superchargers - but not the blown engines that follow. :D

Sick nasty build.......errrrrr... I mean bitchin' man. Is that not the lingo that fits the carburator generation?

Don't know why I was runnin' 11lbs of boost..............OH hell, it was fun! She's running happy now at 6lbs. But seriously now is that throttle body injection or a carb? I know you got plenty of great help but I would offer mine to convert that skinny Bronc to Injection.

[Leon Phelps]

Sick nasty build.......errrrrr... I mean bitchin' man. Is that not the lingo that fits the carburator generation?

Don't know why I was runnin' 11lbs of boost..............OH hell, it was fun! She's running happy now at 6lbs. But seriously now is that throttle body injection or a carb? I know you got plenty of great help but I would offer mine to convert that skinny Bronc to Injection.

X2, is that a Projection or a Howell TBI..... I figured you to be a sequential port fuel injection kinda guy!

My fault on the scoop comment, thought the orange beast had a functional scoop.....

[Clint]

X2, is that a Projection or a Howell TBI..... I figured you to be a sequential port fuel injection kinda guy!

My fault on the scoop comment, thought the orange beast had a functional scoop.....


Its a howell setup.

[Wally]

Its a howell setup.

That's what all the kool kids are running on ferd 302's :D

[Steve]

Yep, it's Howell TBI. Simple, relatively cheap, easy to get spare parts and easy to tune. If I have time I might swap cams and go MPI, but I'm doubting that'll happen this winter.

And Courtney, you are correct, the old orange hood scoop was somewhat functional. The new one below is completely open at the back of the scoop so will be somewhat functional as cowl induction.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4475.jpg

[Clint]

That's what all the kool kids are running on ferd 302's :D

302s.........smirk.

[bsaunder]

302s.........smirk.

works for me -
howell's on 302s
SEFI on 351+s
:D

[Swat]

works for me -
howell's on 302s
SEFI on 351+s
:D

Sequential Electronic Fuel Injection
Who wants bank fire?:flipoff2:

[Clint]

works for me -
howell's on 302s
SEFI on 351+s
:D


;)

[Steve]

I'm building it for crawling, not Baja racing. :shrug:

[trailbuilt]

That's what all the kool kids are running on ferd 302's :D

watch it Wally......Technicly You havent "Ran" a ford 302 yet:flipoff2:

[Steve]

watch it Wally......Technicly You havent "Ran" a ford 302 yet:flipoff2:

I have $20 that says he won't run one in 2009. :spit:

[trailbuilt]

I have $20 that says he won't run one in 2009. :spit:

shit we cant bet if we agree.....:D

[Wally]

I have $20 that says he won't run one in 2009. :spit:

I'll take that BET :drunk2: and lets throw another $50 on there that Snotty....oh never mind....lets see some progress pics Steve :D

[Snotty]

My junk runs Wally, yours? Hell, I took the wife to lunch in the jeepster today.

[Steve]

....lets see some progress pics Steve :D

What, you're not following this thread? :flipoff2: Three weeks ago I ran 21 Rd. Today it's an empty shell. Monday all the new sheet metal arrived; wheel tubs, rear quarters and floor pans. In another couple of weeks that will all be installed, meaning the tub will be narrowed. After that's done the tub comes off the frame and the suspension work, along with clocking the Atlas up, begins.

What progress have you made in the last three weeks? :P

[Wally]

...What progress have you made in the last three weeks? :P

yeah yeah yeah, you'll see some this weekend :evil: It's a bit more difficult to work on a rig when it's 50 miles from your house :flipoff2: By the way, did you ever figure out how wide the new tub is going to be when it's all said and done :shrug:

[Steve]

By the way, did you ever figure out how wide the new tub is going to be when it's all said and done :shrug:

At its widest point the stock tub is 65" outside to outside, so after I narrow it it'll be 57".

How does that compare to the outside width of a TJ or YJ?

[rokcrwlrtj]

I believe tub width on a tj is right at 60"

[CSP]

60" is accurate for CJ, TJ, and YJ (not counting flares).

[74BuckinBronc]

That's fine as long as this is the ONLY comparison to a Heep we make, ok Steve?? :tisk: :P :D

J.D.

[Steve]

That's fine as long as this is the ONLY comparison to a Heep we make, ok Steve?? :tisk: :P :D

J.D.

Kathy keeps telling me "just go buy a Jeep" because I'm narrowing it. She gets "the look" each time. :D

[Wally]

Kathy keeps telling me "just go buy a Jeep" because I'm narrowing it. She gets "the look" each time. :D

The "look" like she's right :lolly: We already know she has impecable taste as evidenced by her blue mustang and large bottle of Patrone, and now she's telling you to buy a jeep....seems like she's a bit brighter than you steve :flipoff2:

[clemsonkrawler]

I like the EB.... no one cringes when you dent up a jeep. But people damn near cry when you crush a fender on an EB. Its funny.

[74BuckinBronc]

I like the EB.... no one cringes when you dent up a jeep. But people damn near cry when you crush a fender on an EB. Its funny.

I know I do, and many tears have been shed! :crybaby2:

[Steve]

I've never shed a tear when I've crushed various parts of the current tub, ask Clint. I just keep on going. Of course, it helps that I can fix it myself. ;)

I'm hoping I can quit destroying the rear quarters by narrowing it, but I'll probably just try stupider lines. We'll see... :shrug:

[DaJudge]

Kathy keeps telling me "just go buy a Jeep" because I'm narrowing it. She gets "the look" each time. :D
Wise woman. She was smart enough to pick you, why don't you listen to her? :flipoff2:

[rokcrwlrtj]

your work is so clean it hurts to watch get beat up. I didn't even notice the front end was narrowed until Justin pointed it out.

[Snotty]

Wise woman. She was smart enough to pick you, why don't you listen to her? :flipoff2:

Some might call that a lapse in judgement... :shrug::beer:

[ColoradoXJ]

thanks for letting the sledhead and i come look yesterday... that thing will be sweet!

[Ghettojeep]

Whatever you do, just don't get the stand dirty if its on the other side of the garage. :flipoff2: :D

[JR4X]

At its widest point the stock tub is 65" outside to outside, so after I narrow it it'll be 57".

How does that compare to the outside width of a TJ or YJ?


Looks like you want a flaty. Both of them in my yard are 57" outside and our samy's are 55 the best I can tell by myself. Lookin great Steve!

[THETODD]

Wish I lived over there to come check it out. I may try to get to Moab in November but I don't know yet.

[ammodog76]

Looks good Steve, If i ever get a day off ill try to come over and drool on it....... Im John Macain and i appove this message.

[Steve]

No progress for the last week, been elk hunting. Spending this weekend in the garage and hoping to have the tub cut up and narrowing well under way by tomorrow.

[DaJudge]

No progress for the last week, been elk hunting.
So, how did it go? Bag one? Or just a lot of Scotch and cigars?

[Steve]

So, how did it go? Bag one? Or just a lot of Scotch and cigars?

Yes, filled my cow elk tag, followed by Highland Park 18 y.o. and a very good cigar - 24 hours later after we got it out of the woods. :)

[Clint]

welcome back scuba steve!

[clemsonkrawler]

Yes, filled my cow elk tag, followed by Highland Park 18 y.o. and a very good cigar - 24 hours later after we got it out of the woods. :)

24hours??? Had to go back to the cabin for some more Geritol??:flipoff2:

[ColoradoXJ]

24hours??? Had to go back to the cabin for some more Geritol??:flipoff2:

this, from mr. "not enough tech in the tech threads"

:tisk:

shame on you tejas-lover... SHAME ON YOU.


















































:flipoff2:

steve, get back to it... we wanna see more

[clemsonkrawler]

this, from mr. "not enough tech in the tech threads"

:tisk:

shame on you tejas-lover... SHAME ON YOU.
:flipoff2:

steve, get back to it... we wanna see more

Hes the one talking about hunting, smokin, and drinking in a tech thread. Im just following the lead of our fearless mods.

[Steve]

24hours??? Had to go back to the cabin for some more Geritol??:flipoff2:

It took us almost 24 hours to cut a trail to get the horses to where it was, and yeah, I'm WAY too old to carry elk quarters out on my back. :flipoff2:

Worked on the passenger side floor pan today after running around half the day for some materials. Cut the old floor pan out and test fit the new one. I'll do the driver's side tomorrow and then maybe cut the passenger side off the tub after drilling out about a bazillion spot welds that hold the windshield frame hinge to the tub. :headbang: The braces in the first pic will get 4" cut out of them to narrow it, along with narrowing the new floor pan.

http://www.colorado4x4.org/gallery/files/1/3/1/1/att11931.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/att11913.jpg

[bsaunder]

It took us almost 24 hours to cut a trail to get the horses to where it was, and yeah, I'm WAY too old to carry elk quarters out on my back. :flipoff2:

Worked on the passenger side floor pan today after running around half the day for some materials. Cut the old floor pan out and test fit the new one. I'll do the driver's side tomorrow and then maybe cut the passenger side off the tub after drilling out about a bazillion spot welds that hold the windshield frame hinge to the tub. :headbang: The braces in the first pic will get 4" cut out of them to narrow it, along with narrowing the new floor pan.

Dang - If I'd known you were going to be removing the windshield I would have told you to use a zip gun to just pop off all the welds and then use a new hinge. Way quicker, cleaner, and easier than drilling out the bazillion welds they put on those things from the factory.

[Steve]

Dang - If I'd known you were going to be removing the windshield I would have told you to use a zip gun to just pop off all the welds and then use a new hinge. Way quicker, cleaner, and easier than drilling out the bazillion welds they put on those things from the factory.

I haven't taken it off yet Ben, that's on tomorrow's schedule. I'll try a couple of different things before drilling the spot welds. :thumbsup:

[Steve]

Didn't get as much done today as I'd planned since I had the oldest grandson as a helper. :)

I wanted to cut the passenger side of the tub off, but until I get the floor pan completely welded in and some other stuff done it would fall apart, so I spent the day making the passenger side fit and getting it tack welded in. I then went to the driver's side, which is much worse. Got all the cancer cut out and the floor pan fitted. I then noticed I'm almost out of gas for the MIG. Oh well...

Driver's side new floor pan test fitted:

http://www.colorado4x4.org/gallery/files/1/3/1/1/att37722.jpg


Passenger side new floor pan tack welded in:

http://www.colorado4x4.org/gallery/files/1/3/1/1/att37977.jpg

[SuicideTireZJ]

Yes, filled my cow elk tag, followed by Highland Park 18 y.o. and a very good cigar - 24 hours later after we got it out of the woods. :)

Jesus, I need to learn to read. I saw "...followed by a Highlands Ranch 18 y.o. and a very good cigar" and my first instinct was, wait, he's married! But at least she was legal...

[scottycards]

Wish I lived over there to come check it out. I may try to get to Moab in November but I don't know yet.

Todd- road trip one Saturday soon, if the weather holds out? 6AM depart, GJ by 9 :evil:, play shop beyotch for Steve for a few hours, hand him tools, etc., and then home by dinner?

:evil::evil::evil:

[DaJudge]

Todd- road trip one Saturday soon, if the weather holds out? 6AM depart, GJ by 9 :evil:, play shop beyotch for Steve for a few hours, hand him tools, etc., and then home by dinner?

:evil::evil::evil:
I would suggest a modification after 'hand him tools'--"...burnt meat supper from Steve and home by bedtime."

[Steve]

Todd- road trip one Saturday soon, if the weather holds out? 6AM depart, GJ by 9 :evil:, play shop beyotch for Steve for a few hours, hand him tools, etc., and then home by dinner?

:evil::evil::evil:

:thumbsup:

If the weather's nice we could take the dirt bikes out and see who can hurt themselves the worst. :D


I would suggest a modification after 'hand him tools'--"...burnt meat supper from Steve and home by bedtime."

Scotty doesn't eat meat, but I could burn some veggies on the grill for him. :)

[bsaunder]

ya done yet?

[DaJudge]

Scotty doesn't eat meat, but I could burn some veggies on the grill for him. :)
Cheap date, eh?

[Steve]

ya done yet?

:P

I'll probably cut the passenger side off tomorrow. Here's a pic of the 4" strip that will be cut out to narrow it.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4556.jpg

[Colin]

How complicated will it be with the reduced engine compartment, a problem at all?

[Mike Boyle]

How complicated will it be with the reduced engine compartment, a problem at all?

He already has had the front end narrowed for a while, so it won't be a big deal now.

[Steve]

Like Mike said, the front was already narrowed 8", with no problems. The rest of the tub will match the front now.

[Colin]

so no more fat thighs for the EB, I geet it!

[Steve]

so no more fat thighs for the EB, I geet it!

Edzachery! Them fat thighs keep rubbing on rocks. That hurts. :D

I've been asked several times why I'm making two cuts instead of narrowing the tub in the middle. The firewall has a typical indent in the middle, and the tub has a tunnel for the trans. If I narrowed the middle those would go away, which wouldn't work so, both sides get cut off, a 4" strip gets cut off, and then both sides go back on. The windshield frame will also get narrowed, as will the tailgate, which will still work.

[Steve]

Lots of progress today. Pulled the rear axle and suspension out, as well as the gas tank. Cut the passenger side off the tub, cut the 4" strip out, and tacked the side back on. Lots of finish welding on the passenger side before cutting the driver's side off.

Pics:

After drilling out 30+ spot welds, got the windshield frame off:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4565.jpg


No more rear axle:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4566.jpg


Brace welded in door opening prior to cutting side off:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4567.jpg


Palisade Mike wielding the sawzall:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4569.jpg


Side after cutting off:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4572.jpg

[Steve]

More pics from today. Tub with side and 4" strip cut off:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4575.jpg


Extra metal: :)

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4576.jpg


With the side tacked back on, you can see the difference in the width of the floor pans:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4577.jpg


Side tacked on; the wheel tub is cut out because I have to extend that farther back since I'm moving the rear axle back ~10"

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4579.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4580.jpg


Huge thanks to Palisade Mike and Alex from work; couldn't have gotten nearly as much done today without your help! :hail:

[Colin]

Your making this look way too easy!

I think we all should narrow the rigs. I want my tj to be the width of a golf cart!

[Hippie]

Palisade Mike wielding the sawzall:

What you don't trust Mike with the plasma torch :flipoff2:

[jimminyC]

Man, it looks like you're stripping it down to take it to the scrap yard. There's not much left!

[newracer]

Put a hinge on the windshield so it will be even more like a Jeep! :flipoff2:

[Steve]

Put a hinge on the windshield so it will be even more like a Jeep! :flipoff2:

It already has one. :P

[newracer]

I did not know that. Are you staying with orange?

[74BuckinBronc]

Bronco history, the first broncos 66 & 67 I believe, actually had knobs that held the windshield down on the hood. All of the EB since then have the piano hinge, but few actually drop the windshield.

Blue & Orange right? Denver...bronco...get it...?? LOL

J.D.

[Steve]

Bronco history, the first broncos 66 & 67 I believe, actually had knobs that held the windshield down on the hood. All of the EB since then have the piano hinge, but few actually drop the windshield.

Blue & Orange right? Denver...bronco...get it...?? LOL

J.D.

Yep, I have the long-ass piano hinge that was spot welded more than 30 places. :rant: I've never dropped the windshield, but on this rebuild I'm going to figure out a different hinge arrangement that not only lets me drop it, but take it completely off quickly.

Orange, yes. Blue, no. :P

[74BuckinBronc]

I'd like to see what you come up with. Could be similar to lift-off door hinges, but might be hard to line more than two hinges up, but you need more for proper support and you'd need more than one guy to do it.

[Steve]

Keep in mind that my windshield will be 8" narrower than stock, so significantly lighter. Whether it's two or three hinges, they will be like the lift-off door hinges so that the windshield can be completely removed by sliding it sideways a few inches and lifting it off. Another thing Ford should have thought of years ago...

[scottycards]

Keep in mind that my windshield will be 8" narrower than stock, so significantly lighter. Whether it's two or three hinges, they will be like the lift-off door hinges so that the windshield can be completely removed by sliding it sideways a few inches and lifting it off. Another thing Ford should have thought of years ago...

I love dropping the winshield when I go wheeling, Steve. And my old 1968 CJ5 had a similar setup to what you mention, in that you could drop the 'shield, and take it off in just a couple of minutes.

Worked great. Wind in the face rocks when you're out on a trail. (unless it's super dusty, of course).

Lookin' GOOD. :hail:

[bsaunder]

Keep in mind that my windshield will be 8" narrower than stock, so significantly lighter. Whether it's two or three hinges, they will be like the lift-off door hinges so that the windshield can be completely removed by sliding it sideways a few inches and lifting it off. Another thing Ford should have thought of years ago...

what about leaving the piano hinge and instead of re-welding it, use ~6-8 Dzus fasteners to attach it?

[Steve]

what about leaving the piano hinge and instead of re-welding it, use ~6-8 Dzus fasteners to attach it?

Maybe... When the windshield is up the two sides of the piano hinge are flat against each other, so any fastener there will have to be absolutely flush with the hinge, which as you know is pretty thin sheet metal. I'll figure something out; who knows, maybe I'll patent it, sell it, and get filthy rich. :D

[clemsonkrawler]

Keep in mind that my windshield will be 8" narrower than stock, so significantly lighter. Whether it's two or three hinges, they will be like the lift-off door hinges so that the windshield can be completely removed by sliding it sideways a few inches and lifting it off. Another thing Ford should have thought of years ago...

You can use YJ(or cj/tj) style door hinges. Single half barrel hinge and a pair should be plenty strong enough.

[Steve]

You can use YJ(or cj/tj) style door hinges. Single half barrel hinge and a pair should be plenty strong enough.

That's one option I'll look at. Those hinges are a lot thicker than the EB hinge though... I can't see ever folding it down onto the hood if I can remove it, so it doesn't really even have to be a hinge, just some way to quickly install, remove, and hold the windshield on securely when it's on.

[BURNTFISH]

How about using the tj style window hinge and just use 2 of the same side then it would just slide out to the side.

[Daves75]

Holy Crap, see what happens when you are not around for awhile! I will be paying close attention, to this build. Keep the info coming Steve.

[MtnRunner]

Steve, are you eventually going to weld new outer metal skins on or use filler on the ones that are on it now to straighten it out? I replace mine on my 66'. It was tough keeping everything all lined up and keeping the heat from warping the long panels.

[Steve]

Steve, are you eventually going to weld new outer metal skins on or use filler on the ones that are on it now to straighten it out? I replace mine on my 66'. It was tough keeping everything all lined up and keeping the heat from warping the long panels.

I already have new lower rear quarters for both sides and a new upper rear quarter for the passenger side. As bad as mine are it's far cheaper and easier for me to replace them than to fix what's on there now.

[74BuckinBronc]

Steve, what are you going to do to prevent the rust at the seam in the rear quarters? It'd be cool to run some reinforcing tube behind the skin there in case you lean it into an obstacle, but I don't know if it's worth the weight added.

J.D.

[Steve]

Steve, what are you going to do to prevent the rust at the seam in the rear quarters? It'd be cool to run some reinforcing tube behind the skin there in case you lean it into an obstacle, but I don't know if it's worth the weight added.

J.D.

3M automotive seam sealer. Good stuff.

Clint and I are looking into having an upper quarter panel guard made out of 3/16" steel. It will run from the front to the back and cover the entire upper quarter panel, including a 90* bend at the bottom where the seam is. That should provide more than enough armor to lean it into trees, rocks, or whatever without destroying the underlying sheet metal.

[74BuckinBronc]

Nice! can't wait to see those!! I'd demo a set fer ya! lol. Will they wrap around the rear at all? Some for the front too??

J.D.

[89minitruck]

Holy smokes...

[Steve]

Passenger side is pretty much done including stretching the wheel tub. Got everything welded, and it's solid. Hopefully cut the driver's side off next weekend and finish the tub narrowing. Huge thanks to Dack (BURNTFISH) for helping yesterday. :hail:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4650.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4651.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4653.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4655.jpg

[Steve]

Once it was welded back on the tub solid, I cut the upper and lower quarter panels off since they were beyond repair, and test fitted the new ones. Looks much better. Too bad I can't fit 40" tires with the uncut quarters. :)

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4656.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4661.jpg

[Matt]

Looks great Steve (also looks like a pain in the ass! :D)

[Clint]

Why not take a cue from the old monster garage rig and move the un cut area UP to the top of that body line? Then it still looks unique but is up out of the way. They didnt do a real clean job but its a neat idea.

http://www.rockcrawler.com/features/newsshorts/03april/monster_garage/Bronco-on-Caprice-4.jpg

[74BuckinBronc]

B.U.T.ful! Keep it up!

[BURNTFISH]

How long did it take to finish the welds up.

[Steve]

Why not take a cue from the old monster garage rig and move the un cut area UP to the top of that body line? Then it still looks unique but is up out of the way. They didnt do a real clean job but its a neat idea.

I'll see if it's even possible to do it and make it look right without way more sheet metal and body work than I want to add onto this project. Would look cool.


How long did it take to finish the welds up.

Couple of hours of almost non-stop welding yesterday.

[DANGERRANGER]

im wantin to see the driver side evened out. looks awesome man! are you thinkin about dove tailin it any?

[Steve]

Cutting the driver's side off Friday, and the tub will be narrowed by the end of the weekend. May even have time to narrow the tailgate and windshield frame. No reason to dovetail it since it'll be 8" narrower than stock already, and I'd lose what little storage space I'll still have if I did that. Will post pics of the narrowed tub this weekend.

[Mike Boyle]

What time are you going to be working on it? I have friday off if you need a hand.

[Steve]

Mike, that would be cool. I'll be in the garage most of the day Friday from mid-morning on. Garage is heated, fridge is stocked. :)

[Steve]

As of 11-22 the tub is narrowed 8". Cut the driver's side off today with Palisade Mike's help and got everything tacked back together. Some pics of today's progress:

Mike starting the cutting:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4678.jpg


Driver's side of the tub:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4680.jpg


Not much left after the side's cut off and the wheel well is cut apart to stretch it:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4689.jpg


Stretched wheel well tacked together:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4691.jpg

[Steve]

Using the stock windshield frame to show how much it's been narrowed. I'll narrow the windshield frame and tailgate in the next couple of days after doing the finish welding on the driver's side, then get ready to pull the tub off the frame so I can notch the frame to clock the Atlas up flat.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4693.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4694.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4695.jpg

[Mike Boyle]

Looks good. Sorry I didn't make it by, I got suckered into going down to the parents for turkey day and didn't get back till around noon. Once I got home I just didn't feel like going anywhere else (felt like being lazy). I gotta work on my DD tomarrow at the shop, if I get done early enough I'll swing by and say Hi.

[Steven_Mc]

Wow! Looks good! You're making some great progress on this thing! :hail:

[DANGERRANGER]

looks awesome steve! keep the strong work coming this thing is gonna be a beast when its done

[Steve]

Got some of the finish welding done today on the driver's side, and installed the new passenger side rear quarters. Son came over and helped some. :)

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4699.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4696.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4697.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4700.jpg

[74BuckinBronc]

She's uncut again! Lookin' great Steve! Can't wait to see it a rolling again!

J.D.

[scottycards]

That thing is going to be insane once it's rollin' on 40's Steve.

Insane.

Nice work. Really nice.

[Don-Key]

More more more!!!!!:bounce3::bounce4::beer: Very cool (re) build
I will be watching this one

[Shadow]

How do ya like that parker plasma? I was thinking about getting a similar brand?



http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4700.jpg

[Steve]

How do ya like that parker plasma? I was thinking about getting a similar brand?

Love it. Have had zero problems with it so far, and we've used it a bunch.

[Shadow]

Nice :D. We picked up a 69 Bronco that needs lots of TLC so it's cool checking out these Bronco threads.

[bsaunder]

tap tap tap ........

Anyone workin in here?

:flipoff2:

[Steve]

tap tap tap ........

Anyone workin in here?

:flipoff2:

Nope. :D

Was in Denver last weekend, and am out of town most of this week. I'm taking the week between Christmas and New Year's Day off, and since we're not going anywhere I should get a LOT of work done then. I'm almost ready to pull the tub off. Then I'll notch the frame and clock the Atlas up flat. Install the tub one more time after that to fab the floorpan around the Atlas. Then it'll be time to pull the tub and start the suspension build. Should be there by the end of December. :thumbsup:

[bsaunder]

nice -

I gotta live vicariously through others on EB builds right now.

..I think I have several days of figuring out/remembering what the heck I've done and what I was planning to do before I can start back up on mine...

Maybe if I post the thread up in my garage, then my EB will be inspired to finish itself?:confused: :D

[74BuckinBronc]

Steve, take lots of pics of the Atlas clocking and floor pan modifying. I am anxious to see how you do it. I had to make a small tunner for the front driveshaft with a 2" BL.

J.D.

[Steve]

Steve, take lots of pics of the Atlas clocking and floor pan modifying. I am anxious to see how you do it. I had to make a small tunner for the front driveshaft with a 2" BL.

J.D.

Will do J.D. I only have a 1" BL and won't go any bigger than that. I'll also have to make a new trans crossmember, but that should be easy.

[Frank Z]

Love it. Have had zero problems with it so far, and we've used it a bunch.Can you post a pic of a piece that you've cut with it? Been considering a plasma cutter and really don't know what to expect.

[JimhatTJ]

frank go play with Curts if you want to test out a plasma.

those things rock...

[vaughnb]

Will do J.D. I only have a 1" BL and won't go any bigger than that. I'll also have to make a new trans crossmember, but that should be easy.

The guys that build my 73 managed an Art Carr C-6 with a Stak 3 speed behind it with no BL, a custom tunnel, and new cross member. Went with Tom Woods offset U-Joints on both ends to gain clearance for the front DS. The Stak is clocked about 30 degrees from flat.

[74BuckinBronc]

I could have gotten away with no body mods as well, but I wanted my Atlas flat, and flat it is!

J.D.

[Steve]

Can you post a pic of a piece that you've cut with it? Been considering a plasma cutter and really don't know what to expect.

Could do that this coming weekend. It cuts a very fine, clean cut about 1/16" wide; not really much wider than a sawzall cut and very little cleaning needed on the cut ends.

[Sound_Man]

Can you post a pic of a piece that you've cut with it? Been considering a plasma cutter and really don't know what to expect.

If you want to mess with one Frank come on out. I can show you what I know about mine and what it can do.

[Steve]

I didn't post any pics of the plasma cutter/cuts, because I didn't work on it this past weekend, because I went snowmobiling instead. :)

[74BuckinBronc]

FOCUS man!! ;)

J.D.

[bsaunder]

slacker!

[Bauer]

I didn't post any pics of the plasma cutter/cuts, because I didn't work on it this past weekend, because I went snowmobiling instead. :)

What? I've been waiting for those pics. But you were out goofin off instead..

:P

[Steve]

What? I've been waiting for those pics. But you were out goofin off instead..

:P

It was your fault buddy.

And I'm not complainin' at all. :D

[Steve]

Finally got time to work on it and made good progress. Got the front axle and suspension removed, and narrowed the tailgate. I briefly thought about taking 8" out of one side of the tailgate, but then decided to do it right.


Marked for what will be cut out:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4775.jpg


Both 4" strips cut out and mocked back up:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4782.jpg


Prepped for welding:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4783.jpg


Welded back together. Welding sheet metal with .023 wire (instead of .035) is nice. :)

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4787.jpg

[Steve]

Installed (yes, it fits and opens/closes): :silly:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4788.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4789.jpg


Here's a nice surprise from a previous owner I found inside the tailgate: :mad:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4779.jpg


No front axle or suspension. The crossmember you can see will get cut out to make room for the HP D60.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4790.jpg


Since I'm off work this week I should make a LOT of progress. As soon as I narrow the windshield frame (only one 8" section needs to come out) I'll be ready to pull the tub, notch the frame and clock the Atlas. Should also get the front axle narrowed 4" this week.

[bsaunder]

looking good!

[LS1JKLOVER]

ok, so whats the goo inside the gate,

i dont get it

[Steve]

ok, so whats the goo inside the gate,

i dont get it

Bondo. It was obviously fixed after a wreck by drilling holes to pull it out and then using lots and LOTS of bondo. You can see how thick it is on the cut; that's way too thick. It's fixed correctly now.

[DANGERRANGER]

wreck? he im pretty sure the only straight panel on the rig is the new wheel wells you just installed ha:flipoff2: really though looks good! i cant wait to see some progression this week. :thumbsup:

[Swat]

Is it too late to boatside it? Or is there enough left to do so?

[cracker_1]

Since when do you worry about how the EB looks?? Adding new quarter panels to just dent them again....what a waste LOL Money better spent on beer...LMAO
Looking good Steve!

[Steve]

Is it too late to boatside it? Or is there enough left to do so?

Boatsiding an EB is a lot more work than a JP and, with the tub narrowed, I'd lose most of what's left of the front floorpans, so nowhere to put your feet. With the tub narrowed, and sitting on full width axles on 40's, along with good rocksliders that'll go on later, I should be fine for clearance.

At least it'll look good for a little while Dave. :shrug:

:D

[Swat]

Boatsiding an EB is a lot more work than a JP and, with the tub narrowed, I'd lose most of what's left of the front floorpans, so nowhere to put your feet. With the tub narrowed, and sitting on full width axles on 40's, along with good rocksliders that'll go on later, I should be fine for clearance.

At least it'll look good for a little while Dave. :shrug:

:D

Kinda figured as much. I started a boatside on mine.

WTF would a Red Neck Cracker know about a bronco, Hey Dave!

[Steve]

More done today. Gutted the D60 front so I can narrow the long side 4" and narrowed the windshield frame.


New front axle:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4798.jpg


Yes, that's a bolt broken off in the passenger side knuckle. :mad: That's gonna be fun to get out - NOT!

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4799.jpg


Removed the old piano hinge from the windshield frame. Ford spot welded it on; one of their more dumbass ideas ever. All of those holes are spot welds I drilled out. :headbang: I will NOT be putting it back on with that hinge. I'm going to figure out a hinge setup similar to a <gasp> Jeep door so I can quickly remove the windshield at the trailhead.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4800.jpg


Windshield frame ready to cut. Since I'm narrowing the tub 8" I've made good use of 2" masking tape. :)

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4802.jpg


Windshield frame done - it fits. :D

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4808.jpg


Next on the to-do list is narrow the D60 and clock the Atlas up flat. Then start installing front axle and suspension.

[scottycards]

Good God that's a lot of spot welds to drill out. Feeling your pain on that one. Them spot weld drill bits ain't cheap, either.......

Nice work, Steve. Your rig is going to be insane once it's done.

[cheepin]

For your busted bolt try soaking it for a few days with Wd or PB blaster or the such.Then go buy a EZ out bit.Just drill a hole the appropriate size for the bit and put the EZ out to work.I use a hammer to set the EZ out in a little.True-Value sells them.
And I would copy the window hinge on the older CJs the pre '76 windshields came off.Just lean it forward to about 45* and pull off. Here is a similar setup on my Jeepster's hood.Just lift the hood up and pop it off.Sorry for the bad pic.The pin has 2 flatspots that when lined up with the opening lets it come out.
http://i499.photobucket.com/albums/rr359/Cheepin70/Jeepster.jpg

[Steve]

For your busted bolt try soaking it for a few days with Wd or PB blaster or the such.Then go buy a EZ out bit.Just drill a hole the appropriate size for the bit and put the EZ out to work.I use a hammer to set the EZ out in a little.True-Value sells them.

Fortunately it's sticking out of the knuckle at least 1/4". I'm soaking it now, and will weld a nut to it when I try to remove it. Hopefully I won't need to drill or EZ out.


And I would copy the window hinge on the older CJs the pre '76 windshields came off.Just lean it forward to about 45* and pull off.

I'll definitely check that out, thanks! :thumbsup:

[Clint]

Fortunately it's sticking out of the knuckle at least 1/4". I'm soaking it now, and will weld a nut to it when I try to remove it. Hopefully I won't need to drill or EZ out.



I'll definitely check that out, thanks! :thumbsup:


yup. weld a big nut to it, Ill apply some heat multiple times, and it will come out. Might even do enough with the heat from the welder.

[cheepin]

Should work.I don't have any good pics of my '75CJ-5 I had.The C side was part of the windshield frame and on body was a removable bracket with the pin.It was nice and easy to pull the winshield.For my '80 CJ-7 I ground the pin welds off and beat the pin out.Then used a bolt.
Let us see what you come up with.I need to build a set for the Jeepster.These don't fold but are bolted under the dash.I guess just like a Scout.
Maybee I can use the Jeepster's hood hinges?:idea:I have a regular set of hood hinges and it kind of sucks when you go to lay the hood on the window frame and it pops off.

[Clint]

Spend a couple days bleeding over a 60 and NO PICS. Sheesh :)

60 was cut and narrowed today.

busted off bolt was removed by welding a nut to it and backing it out after it cooled.

It killed Steves chop saw, so the Makita was called into action. Angles were checked and rechecked, triple pass done on the knuckle to make everything secure on the weld up. Beers and dinner were had afterward, and my finger made it though with no psychological aftereffects :)

[Steve]

Spend a couple days bleeding over a 60 and NO PICS. Sheesh :)

60 was cut and narrowed today.

busted off bolt was removed by welding a nut to it and backing it out after it cooled.

It killed Steves chop saw, so the Makita was called into action. Angles were checked and rechecked, triple pass done on the knuckle to make everything secure on the weld up. Beers and dinner were had afterward, and my finger made it though with no psychological aftereffects :)

Dude, I went to bed when I got home. I'm old, remember? :spit:

Yep, the D60 is narrowed, broken bolt is removed from knuckle, passenger side frame rail is cleaned off and Atlas clocking has begun.

And Clint, we didn't smoke the chop saw, the breaker popped. If we'd checked that first instead of pulling the brushes and breaking one we probably would have been fine. I'll get new brushes for it this week. :silly:


Before & after pics of passenger side frame rail:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4814.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4815.jpg


More floor cut out to clock the Atlas up flat: Should get that done today.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4817.jpg

[scottycards]

The front axle narrowing is very interesting- can you share more info and/or pics of that whole process?

I'd like to put one in my TJ some day.

[Steve]

We took a LOT of measurements and discussed the axle narrowing before making the cut. ;)

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4822.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4823.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4824.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4826.jpg


It's cut, that tube is THICK! :eek:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4828.jpg

[Clint]

And Clint, we didn't smoke the chop saw, the breaker popped. If we'd checked that first instead of pulling the brushes and breaking one we probably would have been fine. I'll get new brushes for it this week. :silly:





LOL! The thing that made me think it was shot is the SMOKE that was coming out of it :D

[Steve]

Clint using the smoke wrench to remove the tube from the inner C:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4829.jpg


Inner C ready to reinstall on tube:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4833.jpg


Tube prepped, and inner C fitted onto tube. We used the measurements and angles we took before cutting to make sure it's reinstalled exactly the way it came off.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4834.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4835.jpg


Welding it on. Made three passes with the welder. It's not going anywhere.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4836.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4837.jpg


The finished product. After lots of measuring, considering, discussing, etc. we narrowed it just over 5". I'll have Scott @ Rockstomper cut and respline the shaft, then I'll install new gears and a spool, and as soon as the coilovers arrive it'll get installed under the front. :)

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4838.jpg


Scottycards, I have lots more pics than this, the measurements we took, etc. It's really not that hard to do. It took Clint and I probably 3 hours of actual work.

[Steve]

LOL! The thing that made me think it was shot is the SMOKE that was coming out of it :D

It wasn't happy cutting through that, was it? :D

[Steve]

Got the axle mocked up pretty much where it'll be and cut the front frame crossmember out today. The frame in the pics is about 1" below where I want it at final ride height. The axle is about where it will end up at ride height with 39-40" tires. It's about 3" forward of where the stock EB axle was.


Pretty obvious the crossmember's gotta go:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4839.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4840.jpg


About where it'll end up with the crossmember gone:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4841.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4842.jpg

[DANGERRANGER]

damn man that is one beefy axle:drool: man it must be nice to have all those tools and skills to be able to do all this. awesome progress. keep it comin:thumbsup:

[Mr. Gutwrench]

Inner C ready to reinstall on tube:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4833.jpg




How tight was the "C" on the axle tube? Difficult to install and move into position?

[Steve]

How tight was the "C" on the axle tube? Difficult to install and move into position?

I cleaned up the tube with a flapper wheel so that the C went on tight, but didn't need to be pressed on. We could still rotate it using a dead blow hammer to get it perfect before welding it on.

[Wally]

nice work steve :thumbsup:

[guapotaco]

looks good guys:thumbsup:, now i need one just like it under my taco

[toyin]

Nice progress. The tube and axles look good:beer:

[MtnRunner]

How tight was the "C" on the axle tube? Difficult to install and move into position?


Steve, So once you ground the welds from the old axle tube where it inserts into the "C" the old tube just slides out? Or, was a press involved from the outer side to get the tube stub out?

[CSP]

I can't speak for Steve, but the tube on my D44 was a press fit into the inner C once the welds were cut through. Not having a smoke wrench, I took my sawzall and made two relief cuts through the tube and knocked a small, pie-shaped wedge of the tube out of the C first, making the rest easy to come out (hopefully that makes sense).

When I cut my inner C out I cut through the inner face of the C right through the factory welds. My chopsaw didn't like it at all.

[Clint]

Steve, So once you ground the welds from the old axle tube where it inserts into the "C" the old tube just slides out? Or, was a press involved from the outer side to get the tube stub out?


I can't speak for Steve, but the tube on my D44 was a press fit into the inner C once the welds were cut through. Not having a smoke wrench, I took my sawzall and made two relief cuts through the tube and knocked a small, pie-shaped wedge of the tube out of the C first, making the rest easy to come out (hopefully that makes sense).

When I cut my inner C out I cut through the inner face of the C right through the factory welds. My chopsaw didn't like it at all.

Yup, once the tube was cut, I put the C in a vice and took the tube off at the weld with a bevel so I could see the line and know I was below the weld. After that, we tried the press, but that wasnt gonna cut it. So, back in the vice, and I washed a line down each side of the tube, then beat it out of there with a punch. Once it moved it came out really easy.

[Steve]

As Clint said we tried the press (20T I believe) and when we had enough pressure on it to scare ourselves, we decided to use Plan B. ;)

[Clint]

As Clint said we tried the press (20T I believe) and when we had enough pressure on it to scare ourselves, we decided to use Plan B. ;)

LOL. When the stand is starting to twist up on itself its time to let off.....or stand in the other room or something hehehe

[scottycards]

LOL. When the stand is starting to twist up on itself its time to let off.....or stand in the other room or something hehehe

Gotta love those moments when you're tweaking really hard on something, and one guy stops and turns to the other, and says something like "dude, maybe we should try something else", and the other guy immediately agrees.

Always brings the funny, knowing how dangerous what you were doing was, and knowing you were a little bit lucky to have survived........

:thumbsup::thumbsup:

[Steve]

Gotta love those moments when you're tweaking really hard on something, and one guy stops and turns to the other, and says something like "dude, maybe we should try something else", and the other guy immediately agrees.

Clint was pumping the jack in the 20T press (with his non-stitched hand ;) ), and it was obvious there was a LOT of force on it. He's standing off to the side and I'm backing up and getting behind a customer's Jeep in the shop. That's when we decided Plan B was a good idea. :D

I did briefly think about handing him a length of tube to put on the jack handle to get more force. :spit:

[Steve]

Got the Atlas out today, notched the frame and moved the studs in the Atlas to clock it up. Ran out of energy at that point...

Pulling the Atlas. Much easier out the top then dropping and reinstalling it from underneath. They're heavy suckers.

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4854.jpg


Frame marked for cutting:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4858.jpg


Frame notched and filled back in:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4859.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4862.jpg


Will reinstall the Atlas in the next couple of evenings.

[JR4X]

Freekin sweet :thumbsup:

[bsaunder]

any thought about plating around the outside of the frame at the notch area to beef it up some?

[Steve]

any thought about plating around the outside of the frame at the notch area to beef it up some?

Yep, gonna do that after I pull the tub off, it'll be easier then. ;)

[74BuckinBronc]

Steve, in hindsight, I almost wish I could have plated the outside of the frame with a thick plate, replacing a section of the existing frame. With the way I did it, it's going to be hard to extend my radius arms because the one side of the frame is 1" wider than the other. I guess that's only a concern since I want to try to mount the arms off the side of the frame to maintain a flat belly. Not even sure it's possible, especially with factory width axles, but I hate to waste all that work of making a flat belly.

J.D.

[Steve]

The stock radius arm mounts are getting cut off the frame J.D., so not a concern for me. ;)

[74BuckinBronc]

But, where are you mounting the suspension? Take that into consideration before you stiffen up the frame there.

J.D.

[Steve]

But, where are you mounting the suspension? Take that into consideration before you stiffen up the frame there.

J.D.

:thumbsup:

Part of the reason I'm waiting to do that until the tub is removed and front suspension is built and installed. That will happen as soon as the coilovers arrive. :)

[74BuckinBronc]

Cool! I wish I would have put the stiffener tubing inside the frame as opposed to the outside like I did. Live & learn right??

J.D.

[Steve]

I don't believe it needs anything for simple strength. But, all of the sharp corners will have more stress, and more propensity for cracking, than the former smooth frame rail. So, I will plate the outside of the frame just to make sure I never have a Wallyesque frame problem right there. :D

[74BuckinBronc]

Wallyesque

Ha, even Webster knows what that means...sorry Wally, I don't even know you, but, well facts is facts I guess.

J.D.

[Clod Hopper]

With the notch shown, will you always have to remove the tcase from the top, or is there enough room to slide it back and swing it out? If always from the top, will the interior be removeable?

[Steve]

With the notch shown, will you always have to remove the tcase from the top, or is there enough room to slide it back and swing it out? If always from the top, will the interior be removeable?

I made absolutely certain that the notch is more than long enough to slide the t-case backwards from the trans and drop it out the bottom. :thumbsup:

[74BuckinBronc]

Exactly what I did too, but I do not have the option to remove it from the top.

[Steve]

Exactly what I did too, but I do not have the option to remove it from the top.

I won't after fixing the tub floor and having it lined. It was just easier at this point to do it through the top instead of the bottom.

[Clod Hopper]

I won't after fixing the tub floor and having it lined. It was just easier at this point to do it through the top instead of the bottom.

The very reason the body is off my EB now. Too hard to string a new driveline in that narrow frame and fab all the necessary items. Engine hoist to load in a 205 keeps my back much happier. :D

[Steve]

Installed 4.88 gears and full spool in front axle today. Put the Atlas in after moving the studs, but it's not clocked up enough. Guess I'll be calling Advance Adapters Monday morning to order a different clocking ring. :shrug:


D60 goodness:

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4864.jpg

http://www.colorado4x4.org/gallery/files/1/3/1/1/img_4865.jpg

[rokcrwlrtj]

Nice, looks like a textbook pattern also. Did it work out on the first try or did it take about 50 like my front end did?

[Steve]

Nice, looks like a textbook pattern also. Did it work out on the first try or did it take about 50 like my front end did?

Not 50, but not the first one either. Pinion was in and out several times on this install.

Clint says I'm installing gears in John's D44 tomorrow.

[birddog59]

Not 50, but not the first one either. Pinion was in and out several times on this install.

Clint says I'm installing gears in John's D44 tomorrow.

That or taking cover behind it. Looks good man! :beer:

[BURNTFISH]

When we notched the frames on our lowered trucks we would always make the cuts at 45 degree angles or an arch to help with the strength. These are the cheap bolt in ones, but gives an idea of what I'm talking about. We made ours of 1/4 or thicker steel. Sorry I can't get the pics to work on this computer. You can look up c-notch and get lots of pics.

[Steve]

I forgot to post that I tried to reinstall the Atlas Saturday, and the three positions that the EB Atlas allows for mounting to the trans didn't get the bottom above the bottom of the frame rails. :headbang:

Called Advance this morning; they don't make a clocking ring that will get it clocked up flat in an EB "because you'd have to notch the frame to do that and nobody wants to notch the frame." I told them I already did that. They took my name and #, did some research and called me back. :thumbsup: If I sent my case to them they could make me a custom ring. How much $$$? Lots.

Called some machine shops here, found a big one where the manager is a 'wheeler. Just dropped off the case, they're gonna put the entire case on a big milling machine and drill/tap some new holes for me. When I asked how much, he said $50. He's gonna get a good tip for this job. ;)

[scottycards]

Nice, Steve. It's amazing what a little personal conversation with people will get done.

50 bucks and a nice tip, and you're way ahead. Very cool.

[Camp]

That rocks that the guy is going to do that for you. Too bad it is turning out to be such a hassel.

[Steve]

That rocks that the guy is going to do that for you. Too bad it is turning out to be such a hassel.

Not a huge hassle, fortunately. I briefly thought about installing it Saturday and leaving it hanging down below the bottom of the frame, but one of my big goals for the build is a flat belly pan. I'll make sure the guy knows who to call if he needs some body work or cool paint at a great price as he's building a JP right now that will sit on 40's.

[Clod Hopper]

I'll make sure the guy knows who to call if he needs some body work or cool paint at a great price as ....

Who do you have in mind? :flipoff2:

[cheepin]

I forgot to post that I tried to reinstall the Atlas Saturday, and the three positions that the EB Atlas allows for mounting to the trans didn't get the bottom above the bottom of the frame rails. :headbang:

Called Advance this morning; they don't make a clocking ring that will get it clocked up flat in an EB "because you'd have to notch the frame to do that and nobody wants to notch the frame." I told them I already did that. They took my name and #, did some research and called me back. :thumbsup: If I sent my case to them they could make me a custom ring. How much $$$? Lots.

Called some machine shops here, found a big one where the manager is a 'wheeler. Just dropped off the case, they're gonna put the entire case on a big milling machine and drill/tap some new holes for me. When I asked how much, he said $50. He's gonna get a good tip for this job. ;)

Could you PM with the shop.I need to drill and tap my 205.Since no one makes a clocking ring for it.Thanks

[Steve]

PM sent.

[JR4X]

Even a mod cant name drop in his own thread in the pro shop?

PM sent Steve.