1978 Bronco Frame Off Starts 11/7/15
#31
New Sheet Metal Arrived
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.
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.
#33
#34
Panels are from Rust Repair Panels | Auto Body Panels | Replacement Floor Pans
#36
Repairing Rust
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
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
#38
New Welded Metal
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.
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.
#41
#44