Steve83 > 1983 Ford Bronco > open folder Body Repairs

Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
RattleTest01.JPG
2162 hits | 88 KB | Posted: 9/14/08
Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
RattleTest02.JPG
1808 hits | 93.56 KB | Posted: 9/14/08
Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
RattleTest03.JPG
1776 hits | 80.26 KB | Posted: 9/14/08
Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
Using state-of-the-art masking & paint booth technology, I put a few light coats of primer on.
RattleTest04.JPG
1807 hits | 85.08 KB | Posted: 9/14/08
Using state-of-the-art masking & paint booth technology, I put a few light coats of primer on.
After a few seconds, I put on the first topcoat.
RattleTest05.JPG
1838 hits | 89.9 KB | Posted: 9/14/08
After a few seconds, I put on the first topcoat.
Then another topcoat.
RattleTest06.JPG
1811 hits | 88.28 KB | Posted: 9/14/08
Then another topcoat.
After a few minutes, it looks OK. ...at least as good as the rest of the truck.
RattleTest07.JPG
1708 hits | 96.31 KB | Posted: 9/14/08
After a few minutes, it looks OK.

...at least as good as the rest of the truck.
I picked this beauty up at a local junkyard for ~$30. What a steal!
Fender01.JPG
1707 hits | 83.87 KB | Posted: 9/14/08
I picked this beauty up at a local junkyard for ~$30. What a steal!
The used 120-grit pad wasn't cutting it, so I switched to a used 80-grit. When that started coming ...
Fender02.JPG
1678 hits | 89.17 KB | Posted: 9/14/08
The used 120-grit pad wasn't cutting it, so I switched to a used 80-grit. When that started coming ...
It took ~3/4 can of primer to get a few light coats on both sides & inside.
Fender03.JPG
1701 hits | 87.3 KB | Posted: 9/15/08
It took ~3/4 can of primer to get a few light coats on both sides & inside.
This isn't marketed for paint, but it's good enough for this truck.
WagHVLPstain.jpg
594 hits | 72.64 KB | Posted: 3/13/16
This isn't marketed for paint, but it's good enough for this truck.
I didn't expect show-quality from this, but I thought it might save some time.
HVLP1.JPG
2113 hits | 102.64 KB | Posted: 9/15/08
I didn't expect show-quality from this, but I thought it might save some time.
It's actually a REALLY good-looking spatter finish. Too bad that's not what I want. **...
HVLP2.JPG
2027 hits | 104.8 KB | Posted: 9/15/08
It's actually a REALLY good-looking spatter finish.


Too bad that's not what I want.

**...
After a failed attempt with the mighty Wagner HVLP deck stain gun on the inner face, I switched back...
Fender05.JPG
1781 hits | 83.54 KB | Posted: 9/15/08
After a failed attempt with the mighty Wagner HVLP deck stain gun on the inner face, I switched back...
It's building up slowly, and not as bad as I expected.
Fender06.JPG
1735 hits | 68.23 KB | Posted: 9/15/08
It's building up slowly, and not as bad as I expected.
I've emptied & pressure-washed this '95 door, and I'm about to sand it. The factory trim strip remo...
Door01.JPG
1883 hits | 87.43 KB | Posted: 9/16/08
I've emptied & pressure-washed this '95 door, and I'm about to sand it. The factory trim strip remo...
The clearcoat is surprisingly tough - it stood up to the 80-grit sanding better than I thought it wo...
Door02.JPG
1672 hits | 88.83 KB | Posted: 9/16/08
The clearcoat is surprisingly tough - it stood up to the 80-grit sanding better than I thought it wo...
Since this paint was in MUCH better condition than the fender, I only primed where I hit metal.
Door03.JPG
1745 hits | 84.86 KB | Posted: 9/17/08
Since this paint was in MUCH better condition than the fender, I only primed where I hit metal.
Since this paint was in MUCH better condition than the fender, I only primed where I hit metal.
Door04.JPG
1669 hits | 97.95 KB | Posted: 9/17/08
Since this paint was in MUCH better condition than the fender, I only primed where I hit metal.
The first LIGHT coat of paint.
Door05.JPG
1722 hits | 48.82 KB | Posted: 9/17/08
The first LIGHT coat of paint.
The first LIGHT coat of paint.
Door06.JPG
1644 hits | 95.94 KB | Posted: 9/17/08
The first LIGHT coat of paint.
Finished with the black. The light, hazy areas are reflections. I'll (probably) do the tan after i...
Door07.JPG
1651 hits | 84.7 KB | Posted: 9/19/08
Finished with the black. The light, hazy areas are reflections. I'll (probably) do the tan after i...
Finished with the black. I'll (probably) do the tan after it & the fender are installed.
Door08.JPG
1618 hits | 91.45 KB | Posted: 9/19/08
Finished with the black. I'll (probably) do the tan after it & the fender are installed.
The lower rear bolt (13mm) and the one in the door jamb (10mm) are out. With the hood supported, re...
Fender09.JPG
2024 hits | 65.08 KB | Posted: 9/20/08
The lower rear bolt (13mm) and the one in the door jamb (10mm) are out. With the hood supported, re...
First, I removed the battery, tray, starter relay, PA, coffee can, 2ndry air intake, & wheelwell for...
Fender07.JPG
1906 hits | 107.34 KB | Posted: 9/20/08
First, I removed the battery, tray, starter relay, PA, coffee can, 2ndry air intake, & wheelwell for...
With the wheelwell gone, the six 8mm (5/16") bolts at the front of the fender are much easier to acc...
Fender08.JPG
1682 hits | 69.88 KB | Posted: 9/20/08
With the wheelwell gone, the six 8mm (5/16") bolts at the front of the fender are much easier to acc...
The core support rotted out long ago, due to leaking batteries. But that section only holds the for...
Fender12.JPG
1767 hits | 106.28 KB | Posted: 9/20/08
The core support rotted out long ago, due to leaking batteries. But that section only holds the for...
The fender then comes off easily. While it's off, I'll fix the exhaust leak. But the original reas...
Fender10.JPG
3255 hits | 101.22 KB | Posted: 9/20/08
The fender then comes off easily. While it's off, I'll fix the exhaust leak. But the original reas...
The cardboard on the body horn is the shim for adjusting the height of the fender to the door body l...
Fender11.JPG
2286 hits | 92.04 KB | Posted: 9/20/08
The cardboard on the body horn is the shim for adjusting the height of the fender to the door body l...
This is the only reason I'm replacing the fender - the nuts for the battery tray ripped out years ag...
Fender13.JPG
1737 hits | 112.29 KB | Posted: 9/20/08
This is the only reason I'm replacing the fender - the nuts for the battery tray ripped out years ag...
With the fender removed, the hinge bolts are EASY to access.For door alignment, see this post:htt...
Door09.JPG
2240 hits | 49.25 KB | Posted: 9/20/08
With the fender removed, the hinge bolts are EASY to access.

For door alignment, see this post:
htt...
The last time I worked on the hinges, the fender was in-place, and apparently, I forgot to tighten t...
Door10.JPG
1867 hits | 83.19 KB | Posted: 9/20/08
The last time I worked on the hinges, the fender was in-place, and apparently, I forgot to tighten t...
The door has been emptied, and the wiring is loose inside it. It's ready to come off.For more abo...
Door11.JPG
1717 hits | 93.79 KB | Posted: 9/20/08
The door has been emptied, and the wiring is loose inside it. It's ready to come off.

For more abo...
The door has been emptied, and the wiring is loose inside it. It's ready to come off.This is an '...
Door12.JPG
1731 hits | 100.42 KB | Posted: 9/20/08
The door has been emptied, and the wiring is loose inside it. It's ready to come off.

This is an '...
The wiring connectors fit out the hole in the door, but the harness can also be unplugged from the p...
Door13.JPG
1558 hits | 94.37 KB | Posted: 9/20/08
The wiring connectors fit out the hole in the door, but the harness can also be unplugged from the p...
The doors use captive nut plates for the hinge bolts. The body's hinge nut plates are similar, as a...
Door14.JPG
2304 hits | 75.26 KB | Posted: 9/20/08
The doors use captive nut plates for the hinge bolts. The body's hinge nut plates are similar, as a...
The '92-96 door panels interfere with the '80-86 dash slightly, which is why the pad is dimpled & di...
Door15.JPG
1622 hits | 73.32 KB | Posted: 9/20/08
The '92-96 door panels interfere with the '80-86 dash slightly, which is why the pad is dimpled & di...
I got the orange-peel almost PERFECTLY even. With the fender off, aligning the door will be VERY...
Door16.JPG
1814 hits | 89.41 KB | Posted: 9/20/08
I got the orange-peel almost PERFECTLY even.

With the fender off, aligning the door will be VERY...
This is just about where I want it. The weight of the internals should bring the door down just to ...
Door17.JPG
2019 hits | 73.99 KB | Posted: 9/20/08
This is just about where I want it. The weight of the internals should bring the door down just to ...
The door doesn't fit the opening exactly right, but considering what the body has been through, it's...
Door18.JPG
1867 hits | 73.64 KB | Posted: 9/20/08
The door doesn't fit the opening exactly right, but considering what the body has been through, it's...
After a little massaging, the door fits even better.For door alignment, see this post:http://www....
Door19.JPG
1566 hits | 84.89 KB | Posted: 9/20/08
After a little massaging, the door fits even better.

For door alignment, see this post:
http://www....
It's barely visible, but there's a tapering gap between the door & body seal, indicating that THIS e...
Door20.JPG
1584 hits | 45.24 KB | Posted: 9/20/08
It's barely visible, but there's a tapering gap between the door & body seal, indicating that THIS e...
I've re-adjusted the hinges so the lower front edge of the door seals evenly. To make the rear edge...
Door21.JPG
1799 hits | 50.11 KB | Posted: 9/20/08
I've re-adjusted the hinges so the lower front edge of the door seals evenly. To make the rear edge...
To complete the alignment, the latch & strike must be installed. This later style of lock motor mus...
Door23.JPG
1506 hits | 52.31 KB | Posted: 9/20/08
To complete the alignment, the latch & strike must be installed. This later style of lock motor mus...
The '95 door lines match the '82 body lines perfectly. There was actually NO change to the door lin...
Door24.JPG
2240 hits | 95.68 KB | Posted: 9/20/08
The '95 door lines match the '82 body lines perfectly. There was actually NO change to the door lin...
PERFECTION!!!
Fender14.JPG
2224 hits | 66.33 KB | Posted: 10/2/08
PERFECTION!!!
I got sick of seeing the all-black door & fender faster than I expected, so after hunting through ~5...
Tan01.JPG
1702 hits | 51.94 KB | Posted: 10/6/08
I got sick of seeing the all-black door & fender faster than I expected, so after hunting through ~5...
I didn't feel like painting the whole thing at once (& I couldn't find enough newspaper), so I just ...
Tan02.JPG
1646 hits | 65.6 KB | Posted: 10/6/08
I didn't feel like painting the whole thing at once (& I couldn't find enough newspaper), so I just ...
The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu...
Tan03.JPG
1584 hits | 66.81 KB | Posted: 10/6/08
The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu...
The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu...
Tan04.JPG
1682 hits | 69.27 KB | Posted: 10/6/08
The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu...
After a few minutes, I pulled the masking off.
Tan05.JPG
1572 hits | 54.67 KB | Posted: 10/6/08
After a few minutes, I pulled the masking off.
Good enough for me!
Tan06.JPG
1780 hits | 65.97 KB | Posted: 10/6/08
Good enough for me!
Good enough for me! It'll be spread across the rocks & trees at the SuperLift park in Hot Springs s...
Tan07.JPG
1577 hits | 49.5 KB | Posted: 10/6/08
Good enough for me! It'll be spread across the rocks & trees at the SuperLift park in Hot Springs s...
For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a...
TG01.JPG
1576 hits | 54.96 KB | Posted: 6/13/09
For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a...
For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a...
TG02.JPG
1316 hits | 75.98 KB | Posted: 6/13/09
For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a...
The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...
TG03.JPG
1599 hits | 80.56 KB | Posted: 6/13/09
The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...
This is the L outboard end of that body crossmember. It holds the bedrail upright & supports the qu...
TG04.JPG
1438 hits | 78.56 KB | Posted: 6/13/09
This is the L outboard end of that body crossmember. It holds the bedrail upright & supports the qu...
The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...
TG06.JPG
1471 hits | 74.66 KB | Posted: 6/13/09
The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...
This is the R outboard end of that body crossmember. It holds the bedrail upright & supports the qua...
TG05.JPG
1459 hits | 81.18 KB | Posted: 6/13/09
This is the R outboard end of that body crossmember. It holds the bedrail upright & supports the qua...
Before the frame shop worked on it, I couldn't get the t/g this far open (which still isn't all the ...
TG07.JPG
1503 hits | 60.48 KB | Posted: 6/13/09
Before the frame shop worked on it, I couldn't get the t/g this far open (which still isn't all the ...
The main bend in the body crossmember is close to the R body mount, where the visible kink is.
TG08a.JPG
1493 hits | 36.79 KB | Posted: 6/13/09
The main bend in the body crossmember is close to the R body mount, where the visible kink is.
To repair it, I'm going to use this I-beam (because I have it), but it has to be the right length. ...
TG10.JPG
1511 hits | 68.09 KB | Posted: 6/13/09
To repair it, I'm going to use this I-beam (because I have it), but it has to be the right length. ...
The hooks on this ratcheting cargo strap fit perfectly, and the body crossmember is strong enough to...
TG11.JPG
1490 hits | 47.97 KB | Posted: 6/13/09
The hooks on this ratcheting cargo strap fit perfectly, and the body crossmember is strong enough to...
I laid the long beam across the bedrails & put my heaviest ratchet strap over it. The strap is just ...
TG23.JPG
1568 hits | 56.97 KB | Posted: 6/13/09
I laid the long beam across the bedrails & put my heaviest ratchet strap over it. The strap is just ...
As tension rises in the strap, there's a lot of groaning. The short beam is directly above the kink...
TG11a.JPG
2003 hits | 64.83 KB | Posted: 6/13/09
As tension rises in the strap, there's a lot of groaning. The short beam is directly above the kink...
The strap started off just snug, so it's stretching noticeably. The rags are being cut by the immen...
TG11b.JPG
1573 hits | 64.14 KB | Posted: 6/13/09
The strap started off just snug, so it's stretching noticeably. The rags are being cut by the immen...
Yes, the beam is bending, too. And there's a real risk of the jack shooting out from under the beam...
TG11c.JPG
1545 hits | 59.03 KB | Posted: 6/13/09
Yes, the beam is bending, too. And there's a real risk of the jack shooting out from under the beam...
But the body is bending the way I planned, so it's working. For the first time in 5 years, the cabl...
TG12.JPG
1408 hits | 80.12 KB | Posted: 6/13/09
But the body is bending the way I planned, so it's working. For the first time in 5 years, the cabl...
Despite the progress I made with the first pull, I decided to reset & use another jack. This time, ...
TG13.JPG
1643 hits | 65.01 KB | Posted: 6/13/09
Despite the progress I made with the first pull, I decided to reset & use another jack. This time, ...
I was surprised at how easily I was able to bend this 48" Gorilla Bar. Maybe it wasn't designe...
Gorilla.JPG
1443 hits | 76.44 KB | Posted: 6/13/09
I was surprised at how easily I was able to bend this 48" Gorilla Bar. Maybe it wasn't designe...
This isn't making as much visible progress as the first pull, and I eventually put so much pressure ...
TG14.JPG
1534 hits | 74.82 KB | Posted: 6/13/09
This isn't making as much visible progress as the first pull, and I eventually put so much pressure ...
After the explosion, I reset the cribbing & put a laminated wood board under the short beam to allow...
TG21.JPG
1475 hits | 62.54 KB | Posted: 6/13/09
After the explosion, I reset the cribbing & put a laminated wood board under the short beam to allow...
The rubber pad on the bumper lid is now barely touching the t/g trim panel, just like when I install...
TG15.JPG
1434 hits | 78.74 KB | Posted: 6/13/09
The rubber pad on the bumper lid is now barely touching the t/g trim panel, just like when I install...
It's not visible, but the rubber pad on the bumper lid is now barely touching the t/g trim panel, ju...
TG22.JPG
1406 hits | 55.65 KB | Posted: 6/13/09
It's not visible, but the rubber pad on the bumper lid is now barely touching the t/g trim panel, ju...
The apparent change is 1/2" on the L & 1" on the R.
TG16.JPG
1381 hits | 43.48 KB | Posted: 6/13/09
The apparent change is 1/2" on the L & 1" on the R.
A vast improvement.
TG25.JPG
1542 hits | 88.23 KB | Posted: 6/13/09
A vast improvement.
It's obviously better, though not quite as flat as I had hoped. But the gap between the t/g & bumpe...
TG26.JPG
1626 hits | 61.2 KB | Posted: 6/13/09
It's obviously better, though not quite as flat as I had hoped. But the gap between the t/g & bumpe...