Finally summer is here and the build can begin! Over the winter I have been trying to sell her and because everyone was just kickin the tires.. I kept her!

Goals of the build:
Redo the entire body (again. I get better every year )
-New tailgate
-Mud Flaps
-Install light bar
Completely strip down the interior and redo that
-Rubber flooring
-Sanded/bed liner

A little about the truck before I say the next goal. It's a 1996' XLT 4x4 Bronco. It has a 351W with 299xxx original miles on the engine. I rebuilt the E4OD last year just because I was starting to redo the drivetrain, but there was nothing wrong with it. I also rebuilt the manual BW1356 T-case for the same reason. It still has the stock TTB D44 and Ford 8.8 rear, but they have...Yukon? 4.10s in them (self installed) and they help turn the 33s over so easily.

My final goal of this build, hopefully before summer is over, is to swap in a 94-97 OBS 7.3L Powerstroke with a E4OD (so I can reuse my T-case since it's newer.) I have done quite a bit of research on it so yes I am doing the Powerstroke not the usual Cummins swap.


b1 | Flickr - Photo Sharing!@@AMEPARAM@@http://farm9.staticflickr.com/8241/8660972773_b131f78cdf_m.jpg@@AMEPARAM@@8660972773@@AMEPARAM@@b131f78cdf I don't really have any close up shots of the truck before I started sanding so this is the best I can do.

Untitled | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7324/8733920704_681c089ed4_m.jpg@@AMEPARAM@@8733920704@@AMEPARAM@@681c089ed4 Untitled | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7309/8733920482_371bf70ac2_m.jpg@@AMEPARAM@@8733920482@@AMEPARAM@@371bf70ac2 Those are the main 2 rust spots (there was one more up just behind the door.) Those turned into:
Untitled | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7294/8732803797_13670744cf_m.jpg@@AMEPARAM@@8732803797@@AMEPARAM@@13670744cf Untitled | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7309/8733919400_d0bac8b788_m.jpg@@AMEPARAM@@8733919400@@AMEPARAM@@d0bac8b788 Untitled | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7318/8732812573_ee502edc9e_m.jpg@@AMEPARAM@@8732812573@@AMEPARAM@@ee502edc9e Upper qtr (bare) | Flickr - Photo Sharing!@@AMEPARAM@@http://farm9.staticflickr.com/8550/8747301485_8d40fdb047_m.jpg@@AMEPARAM@@8747301485@@AMEPARAM@@8d40fdb047
After I sanded down the entire quarter panel I started to rebuild.
mesh tape | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7319/8732811207_e8fddbca1a_m.jpg@@AMEPARAM@@8732811207@@AMEPARAM@@e8fddbca1a Mold resistant drywall tape over the holes after getting rid of all the rust.
Fiberglass (upper qtr) | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7312/8747301787_b6b2c17b36_m.jpg@@AMEPARAM@@8747301787@@AMEPARAM@@b6b2c17b36 Fiberglass (lower rear qtr) | Flickr - Photo Sharing!@@AMEPARAM@@http://farm9.staticflickr.com/8277/8748424040_5ce73633e8_m.jpg@@AMEPARAM@@8748424040@@AMEPARAM@@5ce73633e8 Untitled | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7319/8733929528_757783b4e9_m.jpg@@AMEPARAM@@8733929528@@AMEPARAM@@757783b4e9 Untitled | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7299/8732812939_48b411940f_m.jpg@@AMEPARAM@@8732812939@@AMEPARAM@@48b411940f
Sanded that down, Bondo, spot putty then primer.
Quarter panel after | Flickr - Photo Sharing!@@AMEPARAM@@http://farm9.staticflickr.com/8124/8747307741_a5a8c1bbf9_m.jpg@@AMEPARAM@@8747307741@@AMEPARAM@@a5a8c1bbf9 Due to Michigan weather and no garage it took me a week to do this. Next project is the door.

Untitled | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7310/8732808025_d3e9b67d2f_m.jpg@@AMEPARAM@@8732808025@@AMEPARAM@@d3e9b67d2f rust remover | Flickr - Photo Sharing!@@AMEPARAM@@http://farm8.staticflickr.com/7323/8733930928_cf681cbcd3_m.jpg@@AMEPARAM@@8733930928@@AMEPARAM@@cf681cbcd3That is my tent... and the Naval Jelly is AMAZING rust remover.

If I missed some pictures they can all be seen here
Flickr: Fordman96's Photostream

 

Looks like it could be an interesting thread. Unfortunately the pictures you've posted seem to be broken or something.

 

Ya I noticed they aren't working either...


Today I got the driver door sanded, filled and primed (no pictures though...)

Began sanding the 1/2" of Bondo/fiberglass out of the driver side quarter.

 

Nevermind, I tried posting one of the picture I got to work but it wouldn't post. I don't know how flickr works.

Anywho, I hate bondo work, I had an 82 mustang that had plenty of rust holes and we bondoed them. It sucked.

EDIT: And now it won't give me the image code I posted to remove it. Stupid thing!

 

Bondo is simple...
Clear the rust from the hole, cover with mesh tape, fiblerglass Bondo (it's harder to mix it then spread it.) let it cure for 20 minutes then sand it ( or at like 10 minutes use a grater to trim the piece to the shape needed.) Then finish coat it with normal Bondo and sand it smooth... Fill any holes with spot putty and prime.

 

Anyone viewing this know why the pictures will not work? Or know another way to post them? I.e. photo bucket?

 

Don't know why the individual pictures dont come through, but your main link works just fine! To those that can't seem to get it to work, try this link: http://api.viglink.com/api/click?format=go&key=d6a769dd7a35593518c5c56785914b 9d&loc=http%3A%2F%2Fwww.ford-trucks.com%2Fforums%2F1243850-the-wronco.html%23post13177250&v=1&libId=731e2846-9e3f-4544-93c6-414f81129e3e&out=http%3A%2F%2Fapicdn.viglink.com%2 Fapi%2Fclick%3Fformat%3Dgo%26key%3Dd6a769dd7a35593 518c5c56785914b9d%26loc%3Dhttp%253A%252F%252Fwww.f ord-trucks.com%252Fforums%252F1243850-the-wronco.html%26out%3Dhttp%253A%252F%252Fwww.flickr. com%252Fphotos%252F95011313%2540N05%252F%26ref%3Dh ttp%253A%252F%252Fwww.ford-trucks.com%252Fforums%252Fmisc.php%253Fproduct%253 Dvblive&ref=http%3A%2F%2Fwww.ford-trucks.com%2Fforums%2Fmisc.php%3Fproduct%3Dvblive& title=The%20Wronco%20-%20Ford%20Truck%20Enthusiasts%20Forums&txt=Flickr% 3A%20Fordman96's%20Photostream&jsonp=vglnk_jsonp_1 3690121102347

 

Yeah the main links working fine but the individual ones are embedded into the website. If you could right click and do "view image" it would work wit that web address. But since you can't (from what I see) it doesn't post them normal. Photobucket works really well for it and there are many others but I stick with PB.

 

Unfortunately, due to humid weather here in MI I have not been able to get out and work on the truck. Currently I'm sanding down ~1/2 of fiberglass/Bondo on the passenger side quarter panel. I attempted to get a chisel under it and get it to pop off... which started to work UNTIL I put a hole right through the quarter.... After about a half hour of hurtful words, I gave it a rest until I get some more sanding wheels for the angle grinder.


As for a hunt for the 7.3L I have found a few, unfortunately they are a little high on mileage for me (300k-360k) for around $2,000. The local pull-a-part has one with 140k miles on it for $2,000, but since I'm not ready for it I haven't gone and looked too see how much of an eye sore it is.

 

Hmm, can you get to the bondoed parts from the inside? You could take a hammer to it from that side and bang the ever loving **** out of it. It might loosen some of the bondo.

 

No the quarter panel is double ply. It's got the metal for quarter itself then either the rear support or the metal for the inside of the truck. I can hardly fit my hand in there.

 

Use a hole saw to cut a hole on the inside to gain acsess to pound the dent out from the inside. You can then weld the "plug" that you cut out back in and finish the inside.

Been there, done that...........

 

Except I do not have access to a welder at the moment. If I did that would be my option #2. My first option is after I get all the crap off.. to use my torches and heat up the area a little then use a dent puller and see if it will stay in place. (When I first tried messing with the dent it would pop out easily but as soon as you touched it, the panel went back in.

 

Well it's been a while and my girlfriend is out of town so she can't take any pictures (because it's all her fault about it.)

I got the dent out of the quarter panel on the passenger side. I cut out the old holes for the spare tire mount and welded in patches for them.

I had about 5/8" of fiberglass/bondo over the dent in the panel so that was a chore to take out.

I'm currently in the process of sanding/fixing the passenger/fender and I'll be "almost" all done with body work. I need to weld in a patch panel below the pedals and one behind the driver seat before the step up.

After that I'll be moving on to the big swap!!