Purchased a right rear door frame section and two rear 1/4 sections
on a Black Friday Sale which was great.
Now to decide how much of it I need.


New metal for this rusted out part.




How much to cut out don't think I want to get into the fuel door area left side?



How much to cut out right side?



The new metal ($28) for the right ($32) for the left.




Also picked up a new chrome grill ($32) it looked so good I put it on my F350 CS will have to get another one for the Bronco.

 

Nice! Where did you find the new cut outs? I need to do the rear fenders on my 95'

 

Panels are from www.c2cfabrication.com

 

Oh awesome thanks! How is the quality of the cutouts you bought? I'm liking the looks of this.

 

You can get them from rockauto.com or lmc

 

Cut out the left rear 1/4 rust today and worked the new piece in.
Used cut off wheel on a 5" grinder zipped right through it.
Could have used the Plasma cutter but not that much to cut and was
all straight lines.



Laying out the part I will cut out.




Cut out and clamped new metal back in place.



Purchased one of these Flange tools from Harbor Freight. Used it to press a flange into the rear 1/4 cut out for the new piece to lay in. Did a good job may need to go over it couple times. Also has a hole punch to punch metal to make spot like welds.




Kind of hard to show the flanged lip in a photo but can see it on the edge.

Had to stop here to change one of my Mig welders over to .023

 

I'm subscribing to this thread!!

Looks like you have your work cut out for you. I'm sure it'll turn out cherry in the end.

 

Got one of my Mig welders changed over to .024 wire with 75/25 gas and welded the new metal in place.

Had this roll of wire I never used that came with one of the welders when new. Worked just fine with no burn through.




Used this Miller 135 with the settings you see. Some may like it a little cooler but I like a hot welder and move on with the bead.




Put a small tack weld about every 2 inches then ran a bead pushed in with thumb when it needed it.




Looked good from here still need to grind bead down.




Still need to work out something for the inner fender brace don't think I'm putting back what the factory had as its what holds the trash and makes it rust out.

 

boy sure looks great, i need to get rid of this old sears flux machine and get me one of them millers!

 

looking good! I like your comment about the $50 tools is all you need, and then pic of fork lift. That's a tool not many of us have laying around!

 

Well I'm definitely going to follow this. Very steady progress and it makes me want to work on my bronco which I sadly can't touch for 3 years, but hey it's great to see these old broncos getting redone.

 

Subscribing.

Jess

 

Any updates yet???

I'm anxious to see how it's coming along!

 

Finally got time to work on the wheel openings. Go to get one of the long long body sanders bought 2 from Harbor Freight got money back both wouldn't work out of the box.

 

Love the '78 Bronco! Your work is looking good. The most valuable resource IMO is TIME. If only there was more time ... lol