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Body Work and Paint

From 1996 Ford Bronco “'96 Bronco”, documented by Fitzy.

162 photos
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1996 Ford Bronco - The start. In the picture you can see body panels, body filler, al's bed liner, and boat paint. I ended up not going with the boat paint a… 1996 Ford Bronco - I started dismantling the truck in order to work on some rust. 1996 Ford Bronco - Front end of a 1996 Ford Bronco showing significant damage to the grille and fender areas. 1996 Ford Bronco - You can see some pretty bad rust here, another Ford ingenious design created a pocket between the outer and inner panel that built up with… 1996 Ford Bronco - This photo shows a section of a vehicle's frame that has been cut and welded, indicating repair work. 1996 Ford Bronco - This part of a vehicle shows significant rust and damage, indicating repair work is needed. 1996 Ford Bronco - Cutting, rust removing, and prepping. 1996 Ford Bronco - Here I start working on the tire carrier. There was no major rust, but I wanted to repaint it anyways. Most pieces didn't get stripped to b… 1996 Ford Bronco - A metal component is submerged in a bucket of liquid, with various tools scattered around the workbench. 1996 Ford Bronco - Two heavily rusted metal brackets are shown, each with two visible bolt holes. 1996 Ford Bronco - These are some old, heavily rusted metal brackets that appear to be parts from a vehicle. 1996 Ford Bronco - *most pieces* 1996 Ford Bronco - A black metal part with stamped markings is shown close-up against a wooden background. 1996 Ford Bronco - A close-up view of a black bumper corner, showing distinct seam lines and a slightly scuffed surface. 1996 Ford Bronco - Metal parts, possibly for a vehicle, are laid out on newspaper and appear to be freshly painted. 1996 Ford Bronco - Parts are laid out on a workbench, possibly for a vehicle restoration project. 1996 Ford Bronco - Driver-side fender down to bare metal. 1996 Ford Bronco - My workspace for the entire project. Thanks Dad for letting me use the garage. Sometimes it got messy like this. 1996 Ford Bronco - New fender panel placed on with panel adhesive. A friend helped me weld it later on. 1996 Ford Bronco - A close-up view of a shiny metal surface with distinct circular patterns and reflections. 1996 Ford Bronco - Originally I was gonna go with Pacer Flexy-Flares, but I decided I didn't like the look of them over time. They were eventually used on the… 1996 Ford Bronco - A bare metal fender shows signs of bodywork and primer, indicating repairs or preparation for painting. 1996 Ford Bronco - Front view of a 1996 Ford Bronco with the hood open, revealing the engine and surrounding components. 1996 Ford Bronco - Mad Max style. 1996 Ford Bronco - The front end of a Ford truck is shown with the grille and headlights removed, exposing the radiator and other components. 1996 Ford Bronco - Passenger fender was the worst area of the truck. In hindsight I should have just bought a whole new replacement fender. 1996 Ford Bronco - A car door is covered in body filler and has many small holes, indicating it is undergoing repair work. 1996 Ford Bronco - Tailgate rust. Again another Ford ingenious design. I'll call these faults FIDs from now on. 1996 Ford Bronco - The front end of a truck is shown with its hood and grille removed, revealing the engine and radiator components. 1996 Ford Bronco - Taking the paint off the hood. Luckily there weren't many dents so body filler was nice. If you're wondering why I stripped to bare metal f… 1996 Ford Bronco - Another great FID. The rear wheel arch is composed of two pieces. The outer, obviously, and the much unneeded inner arch. The inner arch is… 1996 Ford Bronco - Rear quarter panel of a 1996 Ford Bronco exhibits significant rust and body damage. 1996 Ford Bronco - The crease I talked about earlier. 1996 Ford Bronco - Cutting out the wheel arch was easy, riveting the new panel on was harder. 1996 Ford Bronco - The rear wheel well of a vehicle has been cut open, revealing rust and damage to the inner body panels. 1996 Ford Bronco - I stripped the inner arch the best I could before painting. 1996 Ford Bronco - Various automotive repair products are arranged on a workbench, suggesting preparation for body work or painting. 1996 Ford Bronco - POR15, Rustoleum undercoating, and rubberized undercoating were my best friends for this project. POR15 goes on hard as a rock, I don't see… 1996 Ford Bronco - Detail of a vehicle's wheel well and lower body panel, covered with protective cardboard during work. 1996 Ford Bronco - One of my three attempts at prepping the tailgate. 1996 Ford Bronco - Rusted wheel well opening on a vehicle, showing damage and debris. 1996 Ford Bronco - A large, unidentifiable metal panel sits outdoors in a grassy area next to a tree. 1996 Ford Bronco - I believe I achieved golden redneck status this day. 1996 Ford Bronco - This SUV's rear quarter panel shows significant rust and damage, with a section cut out. 1996 Ford Bronco - Instead of replacing the FID steel inner arch, I opted to just throw in the old plastic liners. It worked well to stop rocks and mud from k… 1996 Ford Bronco - A bare metal hood, likely undergoing restoration or preparation for paint, is shown in a workshop setting. 1996 Ford Bronco - The windshield cowl was an overall pain. Like other obscure parts, there are no replacements made anymore. I had to stick with this panel. 1996 Ford Bronco - Now, thanks to my Dad, I got the opportunity to learn some body work at a Ford Dealership's body shop! Please excuse my Ford-Ingenious-Desi… 1996 Ford Bronco - Fender undergoing bodywork and repair in a workshop setting. 1996 Ford Bronco - A car hood is being sanded and prepped for paint in a workshop setting. 1996 Ford Bronco - After a bit of welding and body filler-ing, we took to priming the fenders and hood. 1996 Ford Bronco - A car door panel is being prepped for paint in a workshop environment. 1996 Ford Bronco - A car fender is shown with metal pins inserted, likely for bodywork or repair. 1996 Ford Bronco - Hood of a vehicle undergoing repair, showing significant rust damage. 1996 Ford Bronco - Body filler is applied and sanded on a car hood in a workshop. 1996 Ford Bronco - A car fender is being repaired with body filler and sanding tools in a workshop. 1996 Ford Bronco - There was a lot of bondo needed, I gladly supplied my own! 1996 Ford Bronco - A car fender, prepped with green primer and exposed metal, is held by a lift in a workshop. 1996 Ford Bronco - Detail of the rear wheel well and frame, with primer applied to the body panel. 1996 Ford Bronco - A metal patch is being riveted onto the rear fender of a vehicle, indicating body repair work. 1996 Ford Bronco - Finally putting on the quarter replacement panels! My parents and neighbors were very happy for these to finally go on. I used the Eastwood… 1996 Ford Bronco - The rear section of a dark-colored SUV with tan trim displays signs of wear and tear, including rust spots. 1996 Ford Bronco - Working around the gas flap was hard, but it came out nice! 1996 Ford Bronco - Got my very very cracked windshield replaced. Gerber was the cheapest option, at *pnly* $200 ): 1996 Ford Bronco - Finally starting to strip paint on the rest of the truck. You can see part of the fender in this picture. It stayed in that primer-glide co… 1996 Ford Bronco - A detached rubber seal, likely for a car window, lies on a concrete surface. 1996 Ford Bronco - Various parts like the rear window weatherstripping needed to be replaced, gosh darn dryrot. And why is rubber so expensive? 1996 Ford Bronco - Looking out the side window of a vehicle at a residential area with trees and a street visible. 1996 Ford Bronco - The rear wheel well of a Ford Bronco shows signs of body repair and rust, with the drum brake visible. 1996 Ford Bronco - Redneck status level platinum achieved. 1996 Ford Bronco - Rain and bare steel don't mix. But rain, steel, and a thick layer of paint dust worked out fine. 1996 Ford Bronco - I guess I was going for the albino leopard print ? No really this was just to protect the bare metal from rusting. 1996 Ford Bronco - The hood had major clear coat failure, I can't find a picture but it was pretty much white before stripping. 1996 Ford Bronco - Rain gutters needed to be cleaned out of old seam sealer. An electric wire brush worked well. 1996 Ford Bronco - Got some fender flares off a nice Californian fellow from fullsizebronco.com 1996 Ford Bronco - A vehicle fender, possibly undergoing repair or modification, is shown with a drill and reflector. 1996 Ford Bronco - The plastic header panel was very broken around the headlights. I fabbed up some sheet metal and riveted it on to give structure and a plac… 1996 Ford Bronco - Front view of a 1996 Ford Bronco parked outdoors at night with headlights on. 1996 Ford Bronco - Car roof with primer applied, detailing damage on the A-pillar and roof edge. 1996 Ford Bronco - This Ford Bronco is in the process of being prepped for paint, with primer visible on the body panels. 1996 Ford Bronco - 2nd attempt at tailgate. This was just sad. 1996 Ford Bronco - The rear of a black 1996 Ford Bronco is shown with a temporary wooden support structure and clamps attached to the bumper area. 1996 Ford Bronco - After stripping layers upon layers of bondo, I turned into a yeti. 1996 Ford Bronco - Just as I thought I was getting out of the panel replacement stage, I found more rust. Another FID (ford-ingenious-design) of 1996. Mud wou… 1996 Ford Bronco - The rear quarter panel of a vehicle is shown with rust and primer, indicating it is undergoing body work and paint preparation. 1996 Ford Bronco - FID affected area. 1996 Ford Bronco - Vehicle body panel undergoing repair with a hydraulic jack supporting the frame. 1996 Ford Bronco - The vehicle is undergoing body work, with visible patches of primer and filler on its side. 1996 Ford Bronco - No pictures of the replacement panel on, but it came out very nice. Bondo work really going on the rear driver side. 1996 Ford Bronco - Sometimes you gotta take a break from the repetitive work of applying and sanding body filler. I made a wooden bumper. 1996 Ford Bronco - This vehicle's rear quarter panel is covered in body filler and primer, obscuring its original year and model. 1996 Ford Bronco - The rear quarter panel of a vehicle shows extensive bodywork in progress, with primer and filler applied over damaged areas. 1996 Ford Bronco - Body filler being applied to the rear fender of a 1996 Ford Bronco during bodywork. 1996 Ford Bronco - Body filler work REALLY coming along now!!! I started school 2 weeks from this time, so it was coming down to the last minute. 1996 Ford Bronco - The rear section of a vehicle is shown with body filler applied, indicating preparation for repair or painting. 1996 Ford Bronco - No pictures of the third and final attempt of replacing that tailgate panel. The change in level isn't this noticeable now. 1996 Ford Bronco - A close-up of a vehicle's rear bumper undergoing body work, with a tire visible. 1996 Ford Bronco - This vehicle's rear quarter panel is shown with body filler and primer, indicating preparation for paint work. 1996 Ford Bronco - After I opted out of the boat paint, because it was glossy and my body work just wasn't good enough for that shine, I went with Rustoleum p… 1996 Ford Bronco - Ford Bronco bodywork in progress, primer and filler applied to rear quarter panel. 1996 Ford Bronco - I started applying glaze. Sanded with 320 grit before the glaze, then 600-900 grit afterwords to achieve a smooth finish. 1996 Ford Bronco - The rear quarter panel of a Ford Bronco is shown with primer and filler, indicating repair work is in progress. 1996 Ford Bronco - The rear of a Ford Bronco, likely from the 1980s, is shown with bodywork in progress, including primer and filler. 1996 Ford Bronco - My family, for the first time in the project, really worked to help me now; and I really needed it. It was crunch time! I thank them very m… 1996 Ford Bronco - This 1996 Ford Bronco is shown during bodywork, with primer and repair patches visible on its side. 1996 Ford Bronco - Rear quarter panel of a 1996 Ford Bronco undergoing bodywork and paint preparation. 1996 Ford Bronco - The vehicle's body is being prepped for paint, with visible areas of primer and filler. 1996 Ford Bronco - Even my grandpa, who just moved back to the states, helped a ton. He is a very experienced man, so his expertise on body work helped more t… 1996 Ford Bronco - The interior of a 1996 Ford Bronco shows a gray primer finish and dice hanging from the rearview mirror. 1996 Ford Bronco - The hood of a vehicle is covered in primer, ready for paint, with windshield wipers visible. 1996 Ford Bronco - We sanded off the glaze coat from the fenders and hood, it was very smooth. 1996 Ford Bronco - Grandpa and dad helped to remove a couple broken bolts reminiscent of the tire carrier. We ended up drilling them out and welding nuts on t… 1996 Ford Bronco - First time the top was taken off while I've owned it. What a beautiful site! The top was much lighter than expected, and will be taken off… 1996 Ford Bronco - 1996 Ford Bronco body in primer, showing bodywork in progress. The rear section and interior are visible. 1996 Ford Bronco - The roof of an older vehicle shows significant wear and peeling paint, with a garage visible in the background. 1996 Ford Bronco - This Ford Bronco is undergoing bodywork, showing primer and exposed metal on its side. 1996 Ford Bronco - Time to prime! 1996 Ford Bronco - An orange SUV is shown with its doors removed, undergoing work in a garage. 1996 Ford Bronco - Front view of a brown Ford Bronco, likely undergoing restoration, with garage items in the background. 1996 Ford Bronco - The interior of a brown SUV is visible from the side, with storage bins in the background. 1996 Ford Bronco - This lifted Ford Bronco, with its top removed, is parked in front of a house and garage. 1996 Ford Bronco - This 1996 Ford Bronco is shown in a garage, appearing to be in the process of being repainted. 1996 Ford Bronco - The running joke those few days were that I should just leave the primer. Infact I agreed, the color of the primer was beautiful, but not w… 1996 Ford Bronco - Replacement rock guard panel being primed. 1996 Ford Bronco - Remember that windshield cowl panel I talked about? It was a pain in the butt to strip, prime, and paint. 1996 Ford Bronco - Side view of an orange vehicle's door and wheel well in a cluttered garage. 1996 Ford Bronco - The top of a vehicle is shown in a garage, with a Ford logo visible on the wall. 1996 Ford Bronco - 5 coats of primer later and it was ready to paint. Again tons of thanks to my family and girlfriend for helping sand, glaze, sand a bunch m… 1996 Ford Bronco - The front of a brown Ford Bronco is shown, with a black SUV parked to the right. 1996 Ford Bronco - First coat of paint on, I used 2 sizes of foam rollers along with foam brushes. It was going on a bit thick. 1996 Ford Bronco - This 1996 Ford Bronco is shown from the side, with its removable top taken off. 1996 Ford Bronco - Side view of a 1996 Ford Bronco in primer, ready for paintwork. 1996 Ford Bronco - This Ford Bronco is undergoing work in a garage, with its roof section removed and seats covered. 1996 Ford Bronco - This Ford Bronco appears to be a fourth-generation model, likely from the early to mid-1990s. 1996 Ford Bronco - I ended up rattlecan spraying these pieces as they could be laid flat. 1996 Ford Bronco - Went ahead and decided to paint the roof rack too at the last minute. Stripped to bare metal, primed with the same stuff I used on the truc… 1996 Ford Bronco - The interior of a 1996 Ford Bronco shows added gauges above the dashboard. 1996 Ford Bronco - More painting! 1996 Ford Bronco - Side view of a 1996 Ford Bronco undergoing body work in a garage. 1996 Ford Bronco - Metal components are laid out on newspaper for painting in a garage setting. 1996 Ford Bronco - Spraying the visor was easy. The paint on it was newish so I just scuffed it and sprayed it with acrylic rustoleum flat black. 1996 Ford Bronco - Car parts are laid out on newspaper and drop cloths, suggesting a painting or restoration project. 1996 Ford Bronco - Final coat of paint went on so I started putting it back together. First time I had a spare tire in months. 1996 Ford Bronco - The black tailgate shows significant peeling paint, revealing exposed metal underneath. This part is from a vehicle undergoing body work. 1996 Ford Bronco - Paint on glass is okay. 1996 Ford Bronco - Not a great picture, but I drenched the bottom of the interior tailgate in undercoating. Not gonna rust anymore, and don't be worried I lef… 1996 Ford Bronco - I covered the glass access with a bunch of garbage bags and duct tape to stop water leaking out. 1996 Ford Bronco - First time with door panels in 6 months. 1996 Ford Bronco - My driverside mirror to door support kept breaking so I investigated. The fault was in a spot weld connecting the outer door panel to the i… 1996 Ford Bronco - New chrome windshield trim on. This stuff was expensive but looks amazing. 1996 Ford Bronco - Front view of a car's hood and windshield, showing an antenna and interior details. 1996 Ford Bronco - Windshield cowl installed, along with new weatherstripping between the cowl and hood. 1996 Ford Bronco - Front end all pot together. With those plastic header repairs I finally bought new headlights. 1996 Ford Bronco - Visor installed. 1996 Ford Bronco - Fender flares installed, no painting needed which was very nice. 1996 Ford Bronco - I used the old rubber flexy-flares as inner fender flares. This stops mud from piling on the steel wheel arch lip. FID avoided. Very easy t… 1996 Ford Bronco - Several bicycles are stored underneath a dark, textured surface, possibly the undercarriage of a vehicle. 1996 Ford Bronco - Gas flap installed. 1996 Ford Bronco - A roof rack is installed on the roof of a white vehicle, seen inside a cluttered garage. 1996 Ford Bronco - And it was all put together!!!! 1996 Ford Bronco - This black Ford Bronco is viewed from its side, showing its removable top and off-road tires. 1996 Ford Bronco - Top back on. I haven't repainted it just yet because I ran out of time before moving into college, but it looks great. I am still debating…