AsBought.JPG
1812 hits | 117.38 KB | Posted: 8/30/14
It's a lot worse than it looks...

busted w/s
neither door window works
driver's inside handle broke...

01BumpF.JPG
906 hits | 132.78 KB | Posted: 9/1/14
Just a tiny dent in the recently-new aftermarket front bumper.

01BumpRear.JPG
784 hits | 119.3 KB | Posted: 9/1/14
The factory rear bumper is twisted more severely.

01Center.JPG
951 hits | 135.38 KB | Posted: 9/1/14
I'm going to try brake fluid to remove the spray paint from the plastic centers. Paint stripper dam...

CenterStripped.jpg
721 hits | 54.9 KB | Posted: 3/29/16
This was ruined when the PO painted it black. I couldn't save it.

01Ketchup.JPG
1843 hits | 126.29 KB | Posted: 9/1/14
The water pump is still shiny & clean, so I can't imagine why there's THIS MUCH rust in the coolant....

01Quarter.JPG
848 hits | 115.37 KB | Posted: 9/1/14
This is the dent that I intentionally left to remind him to be more careful.

01Rub.JPG
745 hits | 114.78 KB | Posted: 9/1/14
This rub pad is stretched because the rubber bumper is too sticky, and the upper sleeve is gone, all...

01Swing.JPG
792 hits | 92.08 KB | Posted: 9/1/14
There should be a thick plastic sleeve around the tube, but they all degrade, and there's no replace...

01Carpet1.JPG
726 hits | 111.44 KB | Posted: 9/6/14
There was a load of crap back here, including leaking bottles of PSF & ATF, drink cups (whose erstwh...

01Carpet2.JPG
756 hits | 119.65 KB | Posted: 9/6/14
At least it smells better now.

01Carpet4.JPG
779 hits | 128.63 KB | Posted: 9/6/14
This looks just about how I remember it, other than the buckle in the driver's footwell from the wre...

01Floor.JPG
771 hits | 120.49 KB | Posted: 9/7/14
I hope I can pound out all those wrinkles in the floor.

InLHF.JPG
933 hits | 116.59 KB | Posted: 9/7/14
It's still actually driveable. If it had a plate & insurance, it would probably even be legal in th...

InRHR.JPG
737 hits | 124.52 KB | Posted: 9/7/14
It's still actually driveable. If it had a plate & insurance, it would probably even be legal in th...

01Wash.JPG
789 hits | 128.22 KB | Posted: 9/7/14
Aaahh... 6 hours of fun & games!

BpillarDrain.JPG
1403 hits | 125.05 KB | Posted: 9/7/14
Now that all that junk is out, water can actually drain.

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

01Yank2.JPG
883 hits | 110.88 KB | Posted: 9/10/14
I'm about to pull those mirrors & the grille reinforcement.

01Yank3.JPG
818 hits | 128.56 KB | Posted: 9/10/14
All the cement is to set the truck & hoist on so they don't sink in the yard when it rains (like my ...

01Strip8.JPG
711 hits | 95.27 KB | Posted: 9/12/14
Squirrel nest under the plenum. Luckily, it doesn't seem like he ate any wiring.

01Strip.JPG
1016 hits | 133.15 KB | Posted: 9/11/14
Despite the torrential rains last night & this morning, it was surprisingly calm & cool this afterno...

01Stripped.JPG
957 hits | 142.71 KB | Posted: 9/11/14
Despite the torrential rains last night & this morning, it was surprisingly calm & cool this afterno...

01Strip5.JPG
1186 hits | 142.13 KB | Posted: 9/12/14
Despite the torrential rains last night & this morning, it was surprisingly calm & cool this afterno...

01Strip10.JPG
1044 hits | 142.82 KB | Posted: 9/12/14
This is so much better after pressure-washing, but the old coolant still stinks.

01Strip11.JPG
958 hits | 134.35 KB | Posted: 9/12/14
I'll probably start removing sheet metal tomorrow.

01Dash8.JPG
899 hits | 143.67 KB | Posted: 9/12/14
Most of the wiring is out now, and after I find storage space for all of this, I'll pull the camper ...

01Ketchuq.JPG
1089 hits | 147.22 KB | Posted: 9/17/14
This is actually MUCH cleaner than the first blast, but I didn't have the camera ready for that one....

02Dash01.JPG
805 hits | 130.62 KB | Posted: 10/13/14
Dash Wiring, right end

02Dash02.JPG
977 hits | 123.07 KB | Posted: 10/13/14
Dash Wiring, center

02Dash03.JPG
784 hits | 136.52 KB | Posted: 10/13/14
Dash Wiring, left end

01Strip14.JPG
880 hits | 137.55 KB | Posted: 10/13/14
The doors came off moments later. Removing the windshield took a couple of hours.

02BodyLift01.JPG
1040 hits | 133.05 KB | Posted: 10/16/14
This electric 2-post lift is endlessly useful.

[url=https://www.supermotors.net/registry/media/3098...

02BodyLift02.JPG
930 hits | 134.19 KB | Posted: 10/16/14

02BodyLift03.JPG
704 hits | 103.91 KB | Posted: 10/16/14

02BodyLift04.JPG
710 hits | 110.58 KB | Posted: 10/16/14

02BodyLift05.JPG
720 hits | 109.1 KB | Posted: 10/16/14

02BodyLift06.JPG
748 hits | 101.97 KB | Posted: 10/16/14

02BodyLift07.JPG
710 hits | 108.52 KB | Posted: 10/16/14

02BodyLift10.JPG
1488 hits | 135.19 KB | Posted: 10/16/14

02BodyLift11.JPG
817 hits | 129.88 KB | Posted: 10/16/14
Everything is still where Ford put it, and working the way Ford designed it to. It's also pretty cl...

02BodyLift12.JPG
757 hits | 127.02 KB | Posted: 10/16/14
This engine still has the early PCV configuration; not the later revision to reduce fouling of #8.

...

02BodyLift13.JPG
789 hits | 135.53 KB | Posted: 10/16/14
[url=http://www.supermotors.net/vehicles/registry/media/1071291][img]http://www.supermotors.net/getf...

02BodyLift14.JPG
766 hits | 131.92 KB | Posted: 10/16/14

02BodyLift15.JPG
761 hits | 142.43 KB | Posted: 10/16/14

02BodyLift16.JPG
708 hits | 131.72 KB | Posted: 10/16/14

02BodyLift17.JPG
711 hits | 134.2 KB | Posted: 10/16/14

02BodyLift18.JPG
746 hits | 123.18 KB | Posted: 10/16/14

02BodyLift19.JPG
751 hits | 130.78 KB | Posted: 10/16/14

03CoreSpt1.JPG
972 hits | 138.81 KB | Posted: 12/4/14
After soaking for about a month, the core support nuts came off easily.

03CoreSpt4.JPG
744 hits | 124.79 KB | Posted: 12/4/14
Both bolts are rusted more than halfway through, but both came out whole. I haven't made ANY progre...

Sleeves01.JPG
793 hits | 121.65 KB | Posted: 1/14/15
3 months of soaking in at least 4 flavors of penetrating oil, and I've managed to separate 2 of the ...

Sleeves04.JPG
758 hits | 126.61 KB | Posted: 1/14/15
With my plate driven between the upper sleeve's flange & the bushing, there was enough preload on th...

Sleeves09.JPG
866 hits | 117.04 KB | Posted: 1/14/15
This was the worst one: LHS cargo bed. I had to build a 2nd tool with a smaller throat, and it stil...

03SeamLeak.jpg
989 hits | 119.18 KB | Posted: 1/29/15
Like the '93XLT tub I used on my truck, this one has some GAPING holes in the factory seams.

[url=h...

04ExManGsktL.JPG
854 hits | 91.95 KB | Posted: 1/29/15
This gasket was installed when the reman engine went in, and although it doesn't appear to be leakin...

04Intake1.JPG
1591 hits | 133.24 KB | Posted: 1/29/15
The plenum & wiring came off easily, but I want to pull the distributor before the fuel rail, and cl...

04Dist.jpg
3600 hits | 129.89 KB | Posted: 1/29/15
Snatching a distributor out without preparing makes it much harder to put back. I prefer to mark th...

04FuelRail.JPG
2562 hits | 137.19 KB | Posted: 1/29/15
It's much easier to get the rail out after the distributor is gone. I prefer to keep the injectors ...

04Intake2.JPG
1015 hits | 137.43 KB | Posted: 1/29/15
These intake gaskets only have ~30Kmi, but the coolant system was severely abused & neglected, which...

04Intake3.JPG
1294 hits | 129.62 KB | Posted: 1/29/15
This proves that all the gunk on the intake is from before - this engine has been sitting ~4.5 month...

04EngMtR.jpg
1183 hits | 113.89 KB | Posted: 1/29/15
Like every other Bronco/F engine I've seen with mounts more than a year old, at least one of these i...

04EngMts.jpg
1119 hits | 115.19 KB | Posted: 2/2/15
Before removing the heat shield to actually inspect it, I'm just going to assume the left mount is r...

04Plugs.JPG
877 hits | 127.86 KB | Posted: 2/2/15
All the basic indications are that this engine was still in pretty good shape, and running OK. It l...

05Eng2.JPG
902 hits | 134.81 KB | Posted: 2/7/15
The yard is dry and the air is warm (enough), so I got the torque converter nuts out and pulled the ...

05Eng4.JPG
1112 hits | 137.46 KB | Posted: 2/7/15
Thankfully, there was no sign of sludge having flaked off the original intake. The timing chain was...

05Eng5.JPG
787 hits | 112.42 KB | Posted: 2/8/15
One timing cover bolt sleeve stayed in the block; the other in the timing cover. I extracted both s...

05Eng6.JPG
1071 hits | 102.79 KB | Posted: 2/8/15
The timing cover is pretty rough around the coolant journals, but I think it'll be OK after planing.

05Froze.JPG
720 hits | 131.05 KB | Posted: 3/16/15
Game called on account of freezing rain, sleet, snow, thaw, snow, and rain (in that order, over the ...

05Gray01.JPG
796 hits | 119.82 KB | Posted: 3/16/15
3 days ago there was ice on the ground; today, I'm sweating in short sleeves & long jeans. But it's...

05Gray02.JPG
730 hits | 102.87 KB | Posted: 3/16/15
These are holding the factory paint better than the pan, but they're getting rinsed with new paint, ...

05Gray03.JPG
764 hits | 108.3 KB | Posted: 3/16/15
The heater outlet Motorcraft KT-81 was wire-wheeled...

05Gray04.JPG
903 hits | 108.93 KB | Posted: 3/16/15
This bore brush used to be fluffy, and the heater outlet pipe [url=https://www.amazon.com/dp/B00809U...

05Gray06.JPG
2044 hits | 133.2 KB | Posted: 3/16/15
All the cast Aluminum parts are clean, and now they're getting a fresh layer of Dupli-Color Aluminum...

05Gray07.JPG
1144 hits | 116.91 KB | Posted: 3/16/15
All the cast Aluminum parts are clean, and now they're getting a fresh layer of cast-coat (DupliColo...

05Gray08.JPG
956 hits | 117.85 KB | Posted: 3/16/15
Now that they're bathed in Duplicolor Engine New Ford Gray DE1611, these might go on tomorrow... I ...

05Gray09.JPG
1318 hits | 97.74 KB | Posted: 3/16/15
I've had a Fumoto QwikValve in my CV for...

05Gray10.JPG
1003 hits | 85.47 KB | Posted: 3/16/15
I've had a Fumoto QwikValve in my CV for...

PlenumT40j.JPG
1652 hits | 118.31 KB | Posted: 3/21/15
No more problems getting at that center bolt, and a common bolt & socket will fit now. IDK why Ford...

05Gray15.JPG
1544 hits | 104.66 KB | Posted: 3/23/15
I don't know why so many people say the factory oil pan bolts won't work with this [url=https://www....

05Gray14.JPG
2891 hits | 109.9 KB | Posted: 3/23/15
After thoroughly cleaning the block - particularly all the gasket surfaces - and getting the timing ...

05Gray13.JPG
1188 hits | 107.38 KB | Posted: 3/23/15
After thoroughly cleaning the block - particularly all the gasket surfaces - and getting the timing ...

05Gray34.JPG
1491 hits | 109.78 KB | Posted: 3/25/15
This WP was relatively new, but its back plate had some rust. I painted both inside & out ([url=htt...

05Gray36.JPG
1423 hits | 135.33 KB | Posted: 3/25/15
The intake has Mahle/Victor MS15202W graphite gasket...

05Gray37.JPG
942 hits | 128.87 KB | Posted: 3/25/15
Forecast for rain, so it's buttoned up, and it'll have a BBQ cover thrown over it.

[url=https://www...

05Gray39.JPG
1338 hits | 112.47 KB | Posted: 4/11/15
This should make it a LOT easier to set timing. The white line is just a paint pen. The timing cov...

05Gray40.JPG
794 hits | 98.02 KB | Posted: 4/11/15
Sandblasting is a lot quicker when there are 2 big compressors running, but I'm gonna have to raise ...

05Gray41.JPG
1663 hits | 124.55 KB | Posted: 4/11/15
These are sanblasted inside & out in preparation for priming & painting INSIDE & OUT. I tried to do...

05Gray42.JPG
837 hits | 113.58 KB | Posted: 4/11/15
Today, these are getting primer (Rustoleum 249340) inside & out, and tomorrow, I'll torch-cure the p...

05Gray43.JPG
1227 hits | 122.99 KB | Posted: 4/12/15
These are now completely coated with primer (Rustoleum 249340), and paint (Rustoleum 7716) applied &...

05Gray44.JPG
2269 hits | 125.35 KB | Posted: 4/12/15
Most of this is just Rustoleum Primer/Sealer 249321, but the pulleys have Rustoleum low-gloss engine...

05Gray45.JPG
1230 hits | 109.76 KB | Posted: 4/12/15
After the DupliColor Aluminum Cast-Coat (DE1650), this is also getting planed on the text, and then ...

05Gray46.JPG
2724 hits | 106.09 KB | Posted: 4/12/15
After wire-wheeling & washing the harmonic balancer & pointer, I painted them Duplicolor Engine New ...

05Gray47.JPG
1942 hits | 136.41 KB | Posted: 4/12/15
The second big load is blasted, including 2 130A 3Gs, a smog pump, a Saginaw bracket, and a set of h...

05Gray49.JPG
759 hits | 122.43 KB | Posted: 4/12/15
I had to run out for a 2nd can of cast coat. I finished the 2nd can of engine grey. I'm using Rust...

05Gray50.JPG
1082 hits | 114.5 KB | Posted: 4/13/15
Both manifolds were significantly warped, most likely due to gaskets being installed when the engine...

05Gray52.JPG
872 hits | 119.51 KB | Posted: 4/13/15
No gaskets this time, just like at the factory. But instead of grease, I'm using red silicone.

[ur...

05Gray54.jpg
1126 hits | 81.55 KB | Posted: 4/13/15
This is actually just a thin layer, and it's going on WET.

[url=https://www.supermotors.net/registr...

05Gray53.JPG
1016 hits | 136.9 KB | Posted: 4/13/15
It's starting to look like an engine again.

[url=http://www.amazon.com/dp/B000C5HQZ0/]Motorcraft RH...

06Bracket01.JPG
2817 hits | 115.05 KB | Posted: 4/13/15
Since the alternator's output is dependent on a solid ground path through the engine block to the ba...

06Bracket02.JPG
2745 hits | 133.42 KB | Posted: 4/13/15
Like its bracket & the engine, I also stripped the paint (DE1650) from the alternator casting & appl...

06Bracket03.JPG
1050 hits | 115.39 KB | Posted: 4/14/15
While the alternators were apart, I sandblasted & painted their cases & pulleys. Then I wire-brushe...

06Bracket05b.jpg
784 hits | 110.72 KB | Posted: 4/14/15
Saginaw PS pump & A/C compressor bracket ready to go on. I'll finish cleaning the pump after the en...

05Gray56.JPG
962 hits | 106.24 KB | Posted: 4/15/15
Making the debossments look new took about 30sec with a common woodworking belt sander. They're abou...

05Gray58.JPG
1397 hits | 117.49 KB | Posted: 4/15/15
I expect this (DE1636) clear to stay clear for a long time since it & the Aluminum Cast-Coat (DE1650...

06Bracket10.JPG
2247 hits | 139.82 KB | Posted: 5/4/15
Having everything painted makes it look better-than-new.

[url=http://www.amazon.com/dp/B000C5HQZ0/]...

06Bracket13.JPG
908 hits | 143.46 KB | Posted: 5/4/15
Having everything painted makes it look better-than-new.

[url=https://www.supermotors.net/registry/...

05Gray61.JPG
1428 hits | 116.51 KB | Posted: 4/25/15
A quick test of the crankcase showed a MASSIVE leak, which I quickly traced to the new [url=https://...

05Gray62.JPG
899 hits | 112.98 KB | Posted: 4/25/15
Just to make sure the machinist hadn't skewed the intake surfaces, I dry-fitted it without gaskets d...

05Gray66.JPG
1229 hits | 131.79 KB | Posted: 4/25/15
This pattern of sealant will keep the crankcase sealed, and each journal isolated, and will allow oi...

05Gray67.JPG
986 hits | 120.32 KB | Posted: 4/25/15
This E6000 bead is along the same lines as on the other side of the [url=https://www.amazon.com/dp/B...

05Gray68.JPG
1183 hits | 144.51 KB | Posted: 4/25/15
After settling the intake so it's level to the block at the ends of the valley, I spun all the bolts...

05Gray69.JPG
725 hits | 114.35 KB | Posted: 4/25/15
This appears to be a better seal than before, but I'll check this, too, after it all dries.

Note th...

05Gray72.JPG
735 hits | 96.59 KB | Posted: 4/25/15
This appears to be a better seal with the RightStuff than before, but I'll check this, too, after it...

05Gray75.JPG
770 hits | 115.54 KB | Posted: 4/25/15
The shim plate is Ford IMPLEMENT gray, but it's clean & has a new foam ring, and it's on. After cup...

05Gray76.JPG
834 hits | 118.01 KB | Posted: 4/25/15
The flexplate is painted, and I chiseled a notch into the crank hub stickout to match the plate's no...

06GasPlate.JPG
686 hits | 124.16 KB | Posted: 5/4/15
This is just cleaned - nothing special. There was an unpainted spot near the edge that has primer/s...

06HangerHolf.JPG
765 hits | 116.34 KB | Posted: 5/4/15
All trucks should have this done so the spring hangers don't rust out.

06Washed1.JPG
679 hits | 131.04 KB | Posted: 5/4/15
For its last wash before underpainting, I rolled the chassis out of the way.

06Washed2.JPG
709 hits | 110.68 KB | Posted: 5/4/15
I filled behind the cowl drains with seam sealer so they won't hold as much sediment.

[url=https://...

06Washed3.JPG
673 hits | 107.24 KB | Posted: 5/4/15
I sealed up some gaps that wouldn't have leaked inside, but they'd have caught mud thrown by the tir...

06Washed7.JPG
648 hits | 88.56 KB | Posted: 5/4/15
This is looking up in front of the fuel filler. CLEAN!

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

06Washed8.JPG
669 hits | 84.83 KB | Posted: 5/4/15
This is looking up the driver's B-pillar. CLEAN!

[url=http://www.supermotors.net/registry/media/10...

06White1.JPG
671 hits | 107 KB | Posted: 5/4/15
Just like on my '83, a white underbelly will make maintenance easier.

06White5.JPG
692 hits | 106.29 KB | Posted: 5/4/15
Just like on my '83, a white underbelly will make maintenance easier.

06White07.JPG
637 hits | 114.1 KB | Posted: 5/5/15
Just like on my '83, a white underbelly will make maintenance easier.

06White08.JPG
617 hits | 88.6 KB | Posted: 5/5/15
Just like on my '83, a white underbelly will make maintenance easier.

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

06White09.JPG
634 hits | 83.8 KB | Posted: 5/5/15
Just like on my '83, a white underbelly will make maintenance easier.

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

06White10.JPG
582 hits | 103.45 KB | Posted: 5/5/15
Just like on my '83, a white underbelly will make maintenance easier.

06White11.JPG
609 hits | 106.71 KB | Posted: 5/5/15
Just like on my '83, a white underbelly will make maintenance easier.

06White12.JPG
722 hits | 109.83 KB | Posted: 5/5/15
Just like on my '83, a white underbelly will make maintenance easier.

The tight gap where the B-pil...

06White17a.jpg
987 hits | 74.63 KB | Posted: 12/16/15
Wheel Arch Rust

The tight gap where the reinforcement meets the quarter panel is like a funnel for ...

06White13.JPG
654 hits | 112.92 KB | Posted: 5/5/15
Just like on my '83, a white underbelly will make maintenance easier.

03FrameLa.JPG
610 hits | 76.96 KB | Posted: 6/1/15
Wow... Sighting down the rearmost frame section (which is straight & flat), I see it aligns with th...

03FrameRa.JPG
612 hits | 74.28 KB | Posted: 6/1/15
Compared to the L side shown in the PREVious pic...

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

03FrameLc.JPG
664 hits | 84.92 KB | Posted: 6/1/15
A higher angle down the L frame rail, which clearly curves to the R.

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

03FrameRc.JPG
664 hits | 85.08 KB | Posted: 6/1/15
The R frame rail is nearly straight. It should bend slightly to the L.

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

03FrameLRac.jpg
1031 hits | 90.87 KB | Posted: 6/1/15
The previous 4 pics combined. Notice how the left rear aligns to the front shock, but the right ali...

06Ypipe.JPG
613 hits | 104.74 KB | Posted: 6/14/15
The Y-pipe is tweaked from the collision, and the muffler isn't rotated correctly, so they need to c...

06Ypull.JPG
559 hits | 98.45 KB | Posted: 6/14/15
I plan to flange these joints eventually, so this won't be necessary again.

06z1.JPG
517 hits | 99.61 KB | Posted: 6/14/15
The frame is nearly empty, but it still has to roll & steer so the trans/t-case can be removed.

06z2.JPG
546 hits | 108.63 KB | Posted: 6/14/15
The frame is nearly empty, but it still has to roll & steer so the trans/t-case can be removed.

06z3.JPG
539 hits | 102.81 KB | Posted: 6/14/15
The frame is nearly empty, but it still has to roll & steer so the trans/t-case can be removed.

06z5.JPG
559 hits | 106.15 KB | Posted: 6/14/15
The frame is nearly empty, but it still has to roll & steer so the trans/t-case can be removed.

ScndryDnstrm.JPG
583 hits | 86.14 KB | Posted: 6/14/15
The downstream 2ndry air pipe was rusted out from the inside, and it took some effort to separate it...

06z7.JPG
520 hits | 113.06 KB | Posted: 6/19/15
I pulled out the brake system & trans/t-case in preparation for the frame swap.

06z8.JPG
575 hits | 111.44 KB | Posted: 6/19/15
The TC is strapped into the bellhousing so it doesn't slide out, and the lines are threaded back int...

07Cat1.JPG
689 hits | 93.84 KB | Posted: 6/19/15
This cat go mashed in the wreck, and most of the substrate is in the 2nd cat. I'm shopping for a re...

07Frame96a.JPG
642 hits | 108.68 KB | Posted: 6/19/15
This has been in the woods for a few years, and there are some pieces missing, which I'll transfer f...

07Frame96e.JPG
585 hits | 113.25 KB | Posted: 6/27/15
It was pretty cool today, so I set the frame onto the trailer & hauled it home.

07Frame96i.JPG
524 hits | 115.01 KB | Posted: 6/27/15
This is after its first rinse in several years. I plan to pressure-wash & cup-brush it a few times ...

07Frame96m.JPG
620 hits | 97.8 KB | Posted: 6/27/15
I sold some parts off this frame several years ago, so there were several rivets to knock through. ...

07Frame96p.JPG
524 hits | 91.53 KB | Posted: 6/27/15
I don't know yet if this SN matches the one stamped on the top of the frame rail.

UPDATE: Turns out...

07Frame96q.JPG
532 hits | 79.46 KB | Posted: 6/27/15
I didn't realize these frames had been made by Hayes/Dana.

07Frame96o.JPG
515 hits | 90.75 KB | Posted: 6/29/15
There were weeds rooting into the decaying leaves in here, which is why it's so rusty.

07Frame96s.JPG
604 hits | 109.97 KB | Posted: 6/29/15
Looking much better after the first pass with the cup brush.

06z11.JPG
569 hits | 106.04 KB | Posted: 7/5/15
I've had all the bolts loose enough to do this for a while, but I wasn't sure everything else was re...

06z13.JPG
519 hits | 97.09 KB | Posted: 7/5/15
To get the rear axle out, I had to raise the back end.

06z17.JPG
536 hits | 103.75 KB | Posted: 7/5/15
I want to weigh this thing, so I found its balance point. Later, I'll rearrange the jack stands so ...

06z18.JPG
617 hits | 105.98 KB | Posted: 7/5/15
This is the balance point for a frame stripped of all bolts, but the only rivets that have been remo...

06z19.JPG
490 hits | 110.84 KB | Posted: 7/7/15
It's very subtle, but the area where the radius arm bracket belongs is rolled inward. The rail is s...

06z22.JPG
686 hits | 96.36 KB | Posted: 7/7/15
I'm salvaging the front section to use as a jig for front bumpers, and I may do the same with the re...

06z23.JPG
552 hits | 89.17 KB | Posted: 7/17/15
I'm keeping the front & rear frame sections to use as bumper jigs, and most of the other parts as sp...

06z24.JPG
581 hits | 94.03 KB | Posted: 7/17/15
Most of these parts will go onto the '96 frame - the rest will be spares. They're all clean, but so...

SpringEyeF1.JPG
861 hits | 111.53 KB | Posted: 7/7/15
These bushings weren't totally shot to hell yet, but they were close. I have a set of black Energy ...

07Frame96t.JPG
814 hits | 73.32 KB | Posted: 7/17/15
This full layer of RustOleum Rubberized Undercoating (593236) will hold up much better than the patc...

07Frame96u.JPG
656 hits | 84.78 KB | Posted: 7/17/15
This full layer of RustOleum Rubberized Undercoating (593236) will hold up much better than the pat...

07Frame96v.JPG
635 hits | 68.81 KB | Posted: 7/17/15
This full layer of RustOleum Rubberized Undercoating (593236) will hold up much better than the patc...

07Frame96w.JPG
558 hits | 78.85 KB | Posted: 7/17/15
This full layer of RustOleum Rubberized Undercoating (593236) will hold up much better than the patc...

07Frame96x.JPG
534 hits | 76.67 KB | Posted: 7/17/15
This full layer of RustOleum Rubberized Undercoating (593236) will hold up much better than the patc...

07Frame96y.JPG
580 hits | 79.61 KB | Posted: 7/17/15
This full layer of RustOleum Rubberized Undercoating (593236) will hold up much better than the patc...

07Hanger1.JPG
519 hits | 86.76 KB | Posted: 7/20/15
The factory paint is thick & tough, but it's not impervious, and scratches lead to HUGE scale farms ...

07Hanger2.JPG
549 hits | 87.92 KB | Posted: 7/20/15
A sandblaster would be better for finishing this, but it doesn't break up this paint well enough to ...

07Hanger3.JPG
502 hits | 88.57 KB | Posted: 7/20/15
Getting all the contours of the frame brackets destroyed my new cup brush. Fortunately, I kept the ...

07Hanger4.JPG
579 hits | 96.96 KB | Posted: 7/20/15
Rear spring hangers going back on. The bolts are red-threadlocked.

07Hanger6.JPG
592 hits | 104.09 KB | Posted: 7/20/15
Rear spring hangers going back on. The bolts are red-threadlocked.

07Hanger8.JPG
708 hits | 88.68 KB | Posted: 7/20/15
I wire-wheeled & painted the spring eye bolts, then coated them with anti-seize lube before installi...

07Hanger11.JPG
637 hits | 91.9 KB | Posted: 7/21/15
These pivot brackets are clean & receiving undercoating, but I can't set the frame back on this axle...

07Hanger12.JPG
527 hits | 72.3 KB | Posted: 7/21/15
Left pivot bracket for the right beam.

07Hanger13.JPG
568 hits | 83.96 KB | Posted: 7/21/15
Right pivot bracket for the left beam.

ShockEye11.JPG
998 hits | 57.74 KB | Posted: 7/28/15
This new shock comes with a rubber bushing that will last 30-60Kmi, but I want one that will last fo...

ShockEye12.JPG
610 hits | 81.81 KB | Posted: 7/28/15
It may take some effort to get the driving socket out of the shock eye, and the bushing out of the r...

ShockEye13.JPG
599 hits | 59.13 KB | Posted: 7/28/15
With a little silicone grease, the new bushing (9.8141G) goes straight into the shock eye with no so...

ShockEye14.JPG
654 hits | 72.57 KB | Posted: 7/28/15
It looks like it belongs there, and can be transferred later to another new shock.

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

07Hanger21.JPG
600 hits | 119.68 KB | Posted: 8/11/15
The heat index dipped into the double-digits for a little while, so I set the frame back on the fron...

07Hanger23.JPG
663 hits | 104.91 KB | Posted: 8/11/15
Keeping the TTB on these jack stands made reinstalling it MUCH easier than the last one I did, but I...

07Hanger25.JPG
1072 hits | 99.66 KB | Posted: 8/11/15
There are still a lot of loose fasteners, but it's coming together. I think when it's done, the onl...

07In1.JPG
623 hits | 104.83 KB | Posted: 8/28/15
I really wanted to clean & paint the trans & t-case, but I couldn't make any worthwhile progress wit...

07In5.jpg
753 hits | 78.16 KB | Posted: 8/28/15
Before setting the engine in, I primer-sealed the front of the torque converter without removing it ...

07In6.jpg
525 hits | 103.21 KB | Posted: 8/28/15
The engine weighs about 550# at this point.

07In7.jpg
577 hits | 87.11 KB | Posted: 8/28/15
With patience, a 32"-long 2x4, and a couple of adjustable straps, I got the engine stabbed onto...

07In8.jpg
530 hits | 45.85 KB | Posted: 8/28/15
The TC studs are also aligned with the flexplate. This is with the engine at #1TDC (0°).

07In9.jpg
496 hits | 54.46 KB | Posted: 8/28/15
These old engine mounts (from another truck) were in surprisingly good shape, so I cleaned & painted...

07In10.jpg
609 hits | 76.01 KB | Posted: 8/28/15
This 32" 2x4 in front of the pan held the trans in perfect position to align with the block.

S...

07In11.jpg
544 hits | 35.52 KB | Posted: 8/28/15
I used blue threadlocker on almost everything, including the starter bolts, TC nuts, & access plate ...

07In12.jpg
571 hits | 53.47 KB | Posted: 8/28/15
The starter is a fresh MotorCraft reman from the dealership.
'92-97 automatic = [url=http://www.amaz...

07In13.jpg
731 hits | 101.39 KB | Posted: 8/28/15
The plenum, alternator, block ground stud & battery/starter harness, PS lines, & MagneFine filters t...

07In14.jpg
597 hits | 83.9 KB | Posted: 8/28/15
The vacuum harness (which I plan to replace with color-matched silicone tubing) is on, and the trans...

07In15.jpg
596 hits | 100.77 KB | Posted: 8/28/15
The vacuum harness is on, and the trans dipstick tube has a fresh coat of paint. The trans heat shi...

07In16.JPG
710 hits | 110.98 KB | Posted: 8/30/15
Looking good...

Motorcraft RH34 Thermostat Housing

07In17.JPG
965 hits | 107.94 KB | Posted: 8/30/15
Looking good...

Eventually, that capped Magnefine in the foreground will be connected to the Sagina...

07In18.JPG
604 hits | 96.35 KB | Posted: 8/30/15
Looking good...

The starter is a fresh MotorCraft reman
'92-97 automatic = [url=http://www.amazon.c...

07In19.JPG
573 hits | 108.38 KB | Posted: 8/30/15
I wirewheeled & galvanized the vapor tubes, but I haven't found their clips or the frame ground bolt...

07In20.JPG
569 hits | 95.81 KB | Posted: 8/30/15
I wirewheeled & galvanized the vapor tubes, but I haven't found their clips or the frame ground bolt...

07In21.JPG
559 hits | 102.64 KB | Posted: 8/30/15
After a little cleaning, I put in the fuel & brake lines.

07In22.JPG
552 hits | 91.39 KB | Posted: 8/30/15
After a little cleaning, I put in the fuel & brake lines. To make it easier later, I separated all ...

07Shaft.JPG
551 hits | 79.51 KB | Posted: 8/30/15
I was hoping to save its original label, but all the ink came off with the first shot of PurplePower...

07TrlRcvr1.JPG
542 hits | 98 KB | Posted: 8/30/15
To make installation & removal easier, I welded these Gr.8 bolts to some light steel so they don't s...

07TrlRcvr2.JPG
595 hits | 74.73 KB | Posted: 8/30/15
Everything is undercoated to resist rust. I set these to form a channel for the wiring harness in t...

07TrlRcvr3.JPG
639 hits | 83.35 KB | Posted: 8/30/15
The rear carriage bolts are from the JY, and I welded them to their square-punched plates to keep th...

07TrlRcvr4.JPG
615 hits | 62.47 KB | Posted: 8/30/15
In addition to red threadlocker, the undercoating should keep the threads clean & usable for many ye...

07Wheel.JPG
645 hits | 102.95 KB | Posted: 10/7/15
I got tired of looking at the black spray-paint on the rims, so I pulled the Aluminum ones off for s...

07Wheels.JPG
783 hits | 89.42 KB | Posted: 10/7/15
After 3 rounds of spraying & scrubbing, they look pretty good. I haven't yet decided if I'll attemp...

08GasTank.JPG
545 hits | 67.6 KB | Posted: 10/3/15
Before mounting the gas tank, I brushed & sealed the nuts, bolts, & washers. I also turned the strap...

08ExhHngr.JPG
771 hits | 81.64 KB | Posted: 10/3/15
This hanger was only used on F-series, but I put one on my '83, and I plan to put this one on this t...

08ExHngr.JPG
766 hits | 86.3 KB | Posted: 10/3/15
Ford installs this hanger with a stud at the rear (right of image) & a nut on top of the crossmember...

08Fan.JPG
1012 hits | 93.85 KB | Posted: 10/4/15
Yesterday, I cleaned & painted the fan ([url=http://www.amazon.com/dp/B000CIYR7W/]Motorcraft YA183[/...

08HXs1.JPG
824 hits | 91.35 KB | Posted: 10/19/15
This core support has acid & collision damage, so I may swap it later. But for now, it's white on t...

08HXs3.JPG
1092 hits | 104.64 KB | Posted: 12/25/15
Yep - radiator fins are clean & straight.

[url=http://www.supermotors.net/registry/media/1068855][i...

08HXs4.JPG
711 hits | 83.18 KB | Posted: 10/19/15
I was hoping to swap in a parallel-flow condenser, but this A/C system is still sealed & working, so...

08HXs6.JPG
719 hits | 97.73 KB | Posted: 10/19/15
It's getting close to complete-enough to run the engine. I ordered a new direct-fit Y-pipe today.

...

08Intakes.JPG
723 hits | 82.88 KB | Posted: 11/2/15
The intake plastics were getting hazy, so I bathed them in black Fusion. I might touch up the inter...

08Intkes.JPG
1329 hits | 45.9 KB | Posted: 11/2/15
The charcoal canister also needed some fresh blackness.

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

08Ja.JPG
727 hits | 94.45 KB | Posted: 11/2/15
I wirewheeled & painted the 2ndry air tubes with engine black, and cleaned the hoses. But I tried s...

SeatLatchR.JPG
588 hits | 94.06 KB | Posted: 11/2/15
This had some pink residue inside & out (like some candy resin), so I stripped & lubed it without fu...

08HXs8.JPG
588 hits | 73.05 KB | Posted: 11/2/15
Just like on my '83, I welded its bolts to these plates so they don't need backup when I R&I the ski...

08HXs9a.JPG
614 hits | 78.58 KB | Posted: 11/2/15
The rusty shift lever was getting noticeable against all the other clean parts, so I gave it some en...

08Muffler2.JPG
603 hits | 100.55 KB | Posted: 11/14/15
To set the flange on this truck's new Y-pipe, I borrowed the original '96 Bronco muffler from my '83...

08Muffler3y.jpg
842 hits | 113.42 KB | Posted: 11/15/15
Using the original '96 Bronco muffler, I positioned my homemade flange on the new Y-pipe, and checke...

08Muffler11y.jpg
831 hits | 77.51 KB | Posted: 11/15/15
After aligning the flange to the original '96 Bronco muffler, I welded it on. My welds are improvin...

08Muffler15y.jpg
1036 hits | 88.02 KB | Posted: 11/16/15
The factory only put this hanger (E6TZ-5A246-B) on F-series Y-pipes, but I think it's a good idea fo...

08Muffler20y.jpg
772 hits | 70.46 KB | Posted: 11/16/15
Yes, I painted the new Y-pipe assembly using HH primer (Rustoleum 249340) & a really old can of HH s...

08Muffler22.JPG
572 hits | 82.54 KB | Posted: 11/16/15
I hope the silver high-heat paint slows the rusting process on the Y-pipe & cats, and sheds mud/dirt...

08Muffler23y.jpg
573 hits | 82.17 KB | Posted: 11/18/15
The new cat already had a heat shield, but it's not as large or correct as the factory shield. With...

08Muffler39a.jpg
1289 hits | 104.19 KB | Posted: 1/7/16
This heavy plasma-cut stainless flange joins the muffler to the Y-pipe just like a stock '96 Bronco'...

ExHanger.jpg
695 hits | 56.12 KB | Posted: 1/7/16
The flange was holding the muffler almost in-position, but this is the mount that will bear its weig...

08Muffler31a.jpg
802 hits | 62.84 KB | Posted: 2/12/17
The downstream secondary air tube was broken, and too thin to weld. Since I don't have a bender to d...

09Tailpipe09.jpg
449 hits | 84.87 KB | Posted: 1/24/19
After a delay (building a new house & shop), I laid out the tailpipe & cut the prebent 2.25-inch sta...

09Tailpipe25.jpg
591 hits | 90.32 KB | Posted: 1/24/19
I tacked it together on the cribbing, and then built the hangers. I plan to flange the muffler-to-t...

09Tailpipe29.jpg
542 hits | 87.93 KB | Posted: 1/24/19
The same fabrication shop that cut the banister panels made these 3/8-inch stainless flanges, just l...

09VacSilicone.jpg
4288 hits | 74.23 KB | Posted: 7/12/19
All the vacuum lines have been replaced with thick-walled (3mmIDx9mmOD) silicone tubing in the same ...

RotarySPOA10-01.jpg
0 hits | 122.69 KB | Posted: 1/18/26
After building a house & shop, I moved it indoors for a little while.

RotarySPOA10-03.jpg
0 hits | 82.61 KB | Posted: 1/18/26
But when I got a 2-post lift to add to the shop, I shoved the chassis out the back.

09VehChs2.jpg
715 hits | 109.92 KB | Posted: 9/2/19
After installing the 2nd lift in the shop, I rolled the chassis & body (separately) outside for a wh...