1.jpg
6106 hits | 73.48 KB | Posted: 11/13/04
TSB 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) IS 6661, P.1
IF THE IMAGE IS TOO SMALL, click it...

2.jpg
3568 hits | 86.38 KB | Posted: 11/13/04
Technical Service Bulletin 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) Instruction Sheet 6661, P...

3.jpg
3181 hits | 56.3 KB | Posted: 11/13/04
TSB 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) I.S. 6661, P.3

[url=http://www.supermotors.net/...

4.jpg
3434 hits | 35.77 KB | Posted: 11/13/04
TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.4

[url=http://www.supermotors.net/regist...

5.jpg
3105 hits | 43.53 KB | Posted: 11/13/04
TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.5

[url=http://www.supermotors.net/vehicl...

6.jpg
2952 hits | 39.9 KB | Posted: 11/13/04
TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.6

[url=http://www.supermotors.net/vehicl...

7.jpg
2883 hits | 32.06 KB | Posted: 11/13/04
TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.7

[url=http://www.supermotors.net/vehicl...

8.jpg
2848 hits | 31.02 KB | Posted: 11/13/04
TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.8

[url=http://www.supermotors.net/vehicl...

9.jpg
3034 hits | 25.77 KB | Posted: 11/13/04
TSB 962011 (supersedes TSB 951409A) I.S. 6661, P.9

The hole at the bottom seems to be sized for the...

Gutter Crack L.JPG
4890 hits | 53.11 KB | Posted: 8/3/03
Drip Rail Cracks

Later, I found these additional cracks:
[url=http://www.supermotors.net/registr...

Gutter Crack R.JPG
4337 hits | 54.18 KB | Posted: 8/3/03
Drip Rail Cracks

Later, I found these additional cracks:
[url=http://www.supermotors.net/registr...

Before.JPG
2512 hits | 50.04 KB | Posted: 5/21/12
This isn't nearly as bad as many that I've seen (including the body I'm moving out of), but since I'...

Ctemplate.JPG
2555 hits | 69.62 KB | Posted: 5/21/12
Don't cut out the paper centers of the holes at the corners, or you won't be able to center-punch th...

Drill.JPG
2451 hits | 47.5 KB | Posted: 5/21/12
After marking the holes & cuts, I checked that the drill bit wouldn't hit the outer skin, and then p...

Excise.JPG
2396 hits | 47.92 KB | Posted: 5/21/12
Join the holes to open the access. An air chisel is quieter, quicker, and safer - especially if the ...

Fan.JPG
2480 hits | 58.52 KB | Posted: 5/21/12
These pics fan across each opening. Note the distinct difference in the lip of the roof panel. The...

Gprep.JPG
2730 hits | 58.07 KB | Posted: 5/21/12
A knotted cup brush on the 4.5-inch grinder strips the paint, and a 1/8-inch drill stops the cracks....

Hweld.JPG
2572 hits | 63.06 KB | Posted: 5/21/12
I'll spare you hi-res pics of my gorilla welding, but I got the holes & cracks closed up with enough...

Inside.JPG
2296 hits | 74.32 KB | Posted: 5/21/12
Some of the primer & foam burned inside, but not as much as I expected.

Junk.JPG
2392 hits | 64.7 KB | Posted: 5/25/12
Since the kits aren't available (I make copies now), I just cut up the scraps from the access holes ...

Kinstall.JPG
2643 hits | 73.99 KB | Posted: 5/25/12
After rough-bending some scrap metal into shape, test-fit it & adjust it a few times. Then scuff al...

Lr.JPG
2450 hits | 56.92 KB | Posted: 5/25/12
Fit & glue the reinforcements. Once the adhesive ([url=https://www.amazon.com/dp/B01J5N8AGS]JB-Kwik...

Plates.JPG
2501 hits | 48.9 KB | Posted: 6/13/12
I found a piece of scrap about the right thickness, cut it into plates, fit them to the body's curve...

QlateInstl.JPG
2511 hits | 50.1 KB | Posted: 6/14/12
After tracking down some 1/4-inch all-steel pop rivets (which are surprisingly RARE) and a rivettool...

DripRailPlates22.jpg
638 hits | 61.06 KB | Posted: 3/23/22
Drip Rail Repair Parts for '80-96 Broncos (16pcs 1/4" steel pop rivets - not shown but availabl...

95BXLTleft.jpg
418 hits | 56.1 KB | Posted: 7/19/22
'78-96 Bronco Drip Rail Repair TSB 95-14-09A
IF THE IMAGE IS TOO SMALL, click it.

After removing th...