89 FSB "Bill"

[Bronco_bucko]

Re: 89 FSB "Bill"

Well, I know it's been a while since I've been on, so I decided if bring this thread up to date on what I've been up to four the last few weeks.

I got the broken rear seat latch bolts drilled out, but instead of tapping the holes, I opted to bore them out, and use grade 8 bolts, nuts, and washers instead. Sorry for the instagram link, but it seems I've since deleted the original photo.

https://www.instagram.com/p/BCfzqaKsczT/

It works, and I'm happy with it.

After cutting my exhaust out, I had a problem with exhaust in the cabin. Installed a cheap turn down, and the fumes stopped coming in the cabin with the rear window down.

[Bronco_bucko]

Re: 89 FSB "Bill"

Earlier this week, I picked up a couple tow hooks from a 2000ish expedition.



Boneyard chargede $10 each. I call that a win.

I brought them home, hung them up, and gave them a quick coat of paint. When I tried to put them up under the bronco for a test fit, there was all kinds of stuff in the way. So, last night, I got to work getting all that stuff out of the way.



First, I started to drill out the rivets for the front air dam, and realized real quick it was more work than I wanted to put in for a shitty piece of plastic. So I got a gators grip on it with on foot on the tire and one on the pumpkin, and proceeded to rip it out. That went much faster.

Then the front sway bar was blocking. So, out it came. I recently purchased a new air compressor and impact gun. Boy, was I glad I finally got that. It makes short work of old frozen bolts.

Once the front sway bar was out, it was only. Logical to pull the rear one as well. Again, impact FTW.

Then I took it for a test drive. Only marginally more body roll, and only with medium to heavy throttle on tight turns. But just driving around town, the suspension feels more forgiving. It's softer on speed bumps and such. I'm pretty happy with the results.

While out on a test drive, I swung by the local Ace Hardware, and grabbed some grade 8 hardware, and headed back home to finish my tow hooks.

I had to widen one existing hole in each side slightly, but once I did, the hooks bolted right up. I'm very pleased with the results.

[Bronco_bucko]

Re: 89 FSB "Bill"

How could I forget?

I also installed a newish rear bumper.



The mounting tabs aren't quite as strong as I'd like, so until I can fix that, I decided to leave the hitch on for a little extra armor. I'd hate for the bumper to get hit, and ruin my tailgate.

[Action]

Re: 89 FSB "Bill"

keep it up.....it is coming along nice.
Jack

[Bronco_bucko]

Re: 89 FSB "Bill"

keep it up.....it is coming along nice.
Jack

Thanks, Action!

So, my done light randomly started working today. It never has since I bought it.



On the bright side (hehe), I have a dome light now. On the dark side, Im back to square one as to why it didn't work before. Guess I'm still going to have to track it down.

[Bronco_bucko]

Re: 89 FSB "Bill"

Pretty excited.

We've had discussion on this forum about where to put a cheap lunchbox locker. Originally, if yall remember, I was going to put a Spartan locker in my straight d44, and leave (for a while) the 9" open. Well, I scoured the Internet for more thoughts, ideas, and opinions. And after it all, I decided to go big instead of going home.

Yesterday, I ordered a Yukon Grizzly Locker for the 9". I realized that I wanted to try it out, and see how bad it could really be.

I was going to go Detroit, but after some reading, it seems the Yukon is at least equal to the Detroit, and a few have said even slightly stronger.

The d44 will still receive a lunchbox locker, but I'm building the 9 first as I can put it under the truck without anyajor modifications. Now that I have the overhaul kit and the locker, all I need is brakes, and some sort of conversion for the u joint to get me by until the driveshaft is ready to be modified later down the road.

Small steps, but definitely progress.

Locker should be delivered by Thursday.

[Bronco_bucko]

Re: 89 FSB "Bill"

Ok. Update time. While acquiring more parts for the 9", I stumbled on a newish front bumper. I hammered out one dent in it about 80%, and it's now it's barely noticeable, and WAY better than the old.





I also ditched the aux lights. They weren't very bright, and I never liked the way the wires were ran.

Then, over this last weekend, after several delays, I finally got my 9" rebuilt with a Yukon Grizzly locker. I had a friend who's a transmission/Gear specialist (go see Tim at Walnut Creek transmission!) come out and show me the ropes on setting up a differential. Gave it some obnoxious paint (primary colors), and bolted it in.



I took it out into a local field for some testing. I'm already seeing a difference in offroad performance. More articulation, more traction.

And I don't know what I was worried about running a full locker. It drives just fine on the street. Totally predictable, and not nearly as loud as I thought it would be. I'm very happy I went big instead of home.



Now that I've got a freshly rebuilt rear end, it's clear to me now how bad of shape my front end is in. It's looking like Im going to have to give the ttb a little love or it may not survive until I'm really for the SAS. Such is life of motorsports. Haha

[Action]

Re: 89 FSB "Bill"

Nice....I run a Detroit in the rear and really like it. It is a little different in the curves (Hills) on/off the gas but not to bad.......The + is I know it is locked up.
Jack

[Bronco_bucko]

Re: 89 FSB "Bill"

It's been too long since I've been on here. Hope yall are doing well. Ive made some more progress on Old Bill the Bronco.

In July '16, my EEC shit the bed, so I decided to upgrade to MAF using Fiveology Racing stage 2 kit. It went in fairly easily, and smoothed out the idle tremendously. Probably helped that I also installed 24lb injectors (I had at least 3 broken factories) and several new sensors, including TPS, IAC, MAP, TFI, and coolant temp sensor.

I also took it our to Minute Muffler in Dublin (Scott has treated me well in the past, and no local shops would do what I wanted) for all new opened up exhaust. While Scott was building my new exhaust, he found one of my Gibson Header collectors tacoed. So I ordered another set. This time, I got cheap Summit Branded Pace Setters, and installed them myself. In doing so, I found the EGR was bad, and while trying to remove it, toasted the EGR tube. So I loaded the parts cannon, and got all new parts for that system. Now it's a 2.5" y pipe to a single 3", into a thrush triple chamber muffler (I didn't want to attract too much attention). It rumbles deep a ought I can set off car alarms, but is actually more manageable and less drone on the highway than the original setup.

I've also been through a couple different sets of wheels.

After the chrome, I found a set of stock wheels, and painted them black.



They looked pretty cool with the new tires I had bought (budget Cordovan Mud Claws 32x11.50), but the offset sucked, so I rubbed at full lock pretty bad.

After those, I got lucky and found my current set on Craigslist.



Also, the powder coated set was a set of 5,so I ordered another tire, and now have a matched set.

The tires, although budget tires, have worked out rather well. This summer I invested in a Viair electric air compressor, so I was able to air down to 15 psi and ran Sourgrass Trail (Rattlesnake Creek). Couldn't have asked any more of the tires than what they gave me.

[Bronco_bucko]

Re: 89 FSB "Bill"

Also, I invested in some better recovery equipment. I got 2x 20' tow straps, and a 1 1/4" snatch rope.

I forgot to mention my EEC fried while trying to put my kid brothers Superduty out of a mud hole just off Slick Rock trail with a chain. 3 hours of impacts fried several electrical components and my neck. This is the reason I decided to invest. �� ��

I also came upon a free topper, so after installing all fresh seals on my original topper with a roof rack, I decided to cut the new(ish) one into a summer topper.

Original winter topper:



New, summer topper:



The new topper has a 51" hole in roof. I have a piece of canvas cut to size, and a butt load of snaps to attach once I get it sewed up. That way, I can shade my kids in hot weather, and open it up when it's a little cooler or under more trees. I also removed the side glass and added shovel mounts. I plan to finish this up by adding expanded metal to the window holes to keep my kids from getting blasted by branches, and adding a custom set of cross bars for a safari rack. (I also bought a welder for various reasons. This year has been good to me.) The soft top I want is over $900. With this project I'll be in less $200 and have better protection for my kids from various elements, and the ability to add mounts for stuff.

Now for the tougher news, and the reason I bought a welder. Old Bill picked up some cancer in the roof. I was originally going to just neutralize the rust a fiberglass the small hole. But once I got digging, it was apparent the rot was worse than I felt fiberglass could fix.

This is how it currently sits. I just did this about two days ago. I had to wait for the rust inhibitor to dry, and in the current weather, I decided to just let it be for a few days. I've never done body work before, but I'm hoping it will turn out mostly OK. I know this truck will never be a show winner, so I'm OK with playing fast and loose with the body work. If it looks good from 50 feet when I'm done, I'll be happy.



Also, I got tired of hanging up on my hitch, so I ditched rear bumper, and flipped the receiver. I gained almost 4" of departure angle.



It definitely made a big difference in clearance.

[Bronco_bucko]

Re: 89 FSB "Bill"

Now, for the plans for this year.

I have been parts collecting like a MFer for the last couple months, trying to get the big ticket and hard to find items.

I took advantage of some time and sales around d black Friday. I tore down the straight axle to figure out what it needs and what is usable. And that's when I decided "F*%& it. Go big or go home." So on Black Friday, I ordered Duff Long Arms and Ruff Stuff diff cover and 9" pinion guard.

I found some rust on the factory 3.54 gears, and just didn't want to chance a noisy front end. Since I also plan on going up a bit in tire size, I plan on 4.56 gears. Because of the carrier break, I'd also need a carrier, so.... Why not an Air Locker? Im right on the verge of ordering gears and locker from Yukon. Probably next week.

In relation to this project, I also ordered the Broncoair setup. Apparently, there's an 8 week backorder on pulleys at the moment. It is what is, so I placed the order.

While at the junkyard, I found a 4 bolt steering box, saginaw pump and bracket, and and air tank off a bagged s10. The guy didn't know how to write it up, so after some haggling, I got this bad boy for $25.



Also, saginaw and 4 bolt box:



Once I had the saginaw, I knew it was time to order the Broncoair setup with saginaw pulley.

It's all coming together, slowly but surely.

Total plans for the straight axle are air locker, 4.56 gears, chromoly shafts, Reid Racing knuckles, and slotted rotors with carbon Metallic pads.

Oh, I also added a light bar I got from an Instagram follower for $30. It was so cheap, I couldn't pass it up.



And now that I have all these accessories I'll need to control, and the headliner and plastics are out of the interior while I fix the roof, I've also got a switch board and gauge pod on the way to start building an overhead console.

Definitely lots to do, and lots to still collect. But it's coming along.