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96-20-11 Bronco Roof Cracks

From 1983 Ford Bronco “That dirty old truck”, documented by Steve83.

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1983 Ford Bronco - TSB 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) IS 6661, P.1 IF THE IMAGE IS TOO SMALL, click it. As far as I know, there are NONE of t… 1983 Ford Bronco - Technical Service Bulletin 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) Instruction Sheet 6661, P.2 ____________________________________… 1983 Ford Bronco - TSB 96-20-11 (supersedes TSBs 90-17-06 & 95-14-09A) I.S. 6661, P.3 [url=http://www.supermotors.net/registry/media/923083] http://www.superm… 1983 Ford Bronco - TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.4 [url=http://www.supermotors.net/registry/media/923084] http://www.supermotors.… 1983 Ford Bronco - TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.5 [url=http://www.supermotors.net/vehicles/registry/media/923696] http://www.sup… 1983 Ford Bronco - TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.6 [url=http://www.supermotors.net/vehicles/registry/media/923697] http://www.sup… 1983 Ford Bronco - TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.7 [url=http://www.supermotors.net/vehicles/registry/media/927478] http://www.sup… 1983 Ford Bronco - TSB 962011 (supersedes TSBs 901706 & 951409A) I.S. 6661, P.8 [url=http://www.supermotors.net/vehicles/registry/media/927628] http://www.sup… 1983 Ford Bronco - TSB 962011 (supersedes TSB 951409A) I.S. 6661, P.9 The hole at the bottom seems to be sized for the seat belt BOLT instead of the NUT, so c… 1983 Ford Bronco - Drip Rail Cracks Later, I found these additional cracks: [url=http://www.supermotors.net/registry/media/929092] http://www.supermotors.net/… 1983 Ford Bronco - Drip Rail Cracks Later, I found these additional cracks: [url=http://www.supermotors.net/registry/media/929092] http://www.supermotors.net/… 1983 Ford Bronco - This isn't nearly as bad as many that I've seen (including the body I'm moving out of), but since I'll never have a better opportunity, I d… 1983 Ford Bronco - Don't cut out the paper centers of the holes at the corners, or you won't be able to center-punch them. Tab the tape so it's easier to tran… 1983 Ford Bronco - After marking the holes & cuts, I checked that the drill bit wouldn't hit the outer skin, and then punched in. 1983 Ford Bronco - Join the holes to open the access. An air chisel is quieter, quicker, and safer - especially if the truck is still assembled. Whatever tool… 1983 Ford Bronco - These pics fan across each opening. Note the distinct difference in the lip of the roof panel. The angled flap on the L may have to be bent… 1983 Ford Bronco - A knotted cup brush on the 4.5-inch grinder strips the paint, and a 1/8-inch drill stops the cracks. During disassembly of my '83 Bronco, I… 1983 Ford Bronco - I'll spare you hi-res pics of my gorilla welding, but I got the holes & cracks closed up with enough material to grind down RELATIVELY smoo… 1983 Ford Bronco - Some of the primer & foam burned inside, but not as much as I expected. 1983 Ford Bronco - Since the kits aren't available (I make copies now), I just cut up the scraps from the access holes in the B-pillars to make my own reinfor… 1983 Ford Bronco - After rough-bending some scrap metal into shape, test-fit it & adjust it a few times. Then scuff all the surfaces for the adhesive, and lay… 1983 Ford Bronco - Fit & glue the reinforcements. Once the adhesive ( JB-Kwik in this case) sets up, apply primer/sealer to the reinforced area. 1983 Ford Bronco - I found a piece of scrap about the right thickness, cut it into plates, fit them to the body's curves, marked & predrilled them, then drill… 1983 Ford Bronco - After tracking down some 1/4-inch all-steel pop rivets (which are surprisingly RARE) and a rivettool, mix the panel adhesive (this is an eq… 1983 Ford Bronco - Drip Rail Repair Parts for '80-96 Broncos (16pcs 1/4" steel pop rivets - not shown but available) IF THE IMAGE IS TOO SMALL, click it. To b… 1983 Ford Bronco - '78-96 Bronco Drip Rail Repair TSB 95-14-09A IF THE IMAGE IS TOO SMALL, click it. After removing the paint & seam sealer in the drip rail,…