Restoration project 1974 Chicago Bronco
We are beginning another project Bronco Restoration. This is a 74 Bronco from Chicago which our customer has decided they want restored for daily driving in and around the Chicago area. We will do a complete ground up frame off restoration. No major customization is planned at this stage. Plans are for fuel injection, limited slip front and rear axles with disc brakes all around, 4" lift, soft top, rain proof interior.
As you can see 34 years living in the Chicago winters has caused a bit of cancer. Unfortunately, this rig will not be able to be saved in its entirety. On the trip here to Norfolk the body mounts collapsed and the body hit the frame. Many, many pounds of rust blew off on the way. The rear bumper even broke off and was laying on the trailer when we arrived here in Norfolk.
We will disassemble everything possible and try to save what is worth being saved. Obviously we will have to replace the tub and all other body panels. It is also obvious we have to start with a new frame for this "frame up" resto!!
Disassembly
With a Bronco in the condition we have to start with like this, we try to salvage everything possible to refurbish and use on the new rig.
Let the Building Begin!
Component Rebuilds
Donor Body is Found
We found this 73 rig out in Colorado. It has 31K original miles on it when it was rolled. Top, windshield frame and passenger side door will be replaced. The inner and outer front clip will also be replaced. But the tub itself is one of the best we have ever received. No rust anywhere on it. A few small dents here and there but no major structural damage.
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We have procured and good frame. Sand blasted, POR15 coated and painted chassis black.
New, Dana 44 front axle is built. 4.11 gears, Trac loc posi, Chevy disc brake conversion kit, Big bearing 9" rear axle was built. 4.11 gears, 31 spline axles, Trac Loc posi, Ford Racing disc brakes.
C4 auto trans is rebuilt with shift kit, J shift Dana 20 T case is completely rebuilt and everything is installed in the chassis with new 4" lift kit
All components are rebuilt. 302 V8 is machined .30 over in the bores, .10 under on the rods and mains. Mild cam is installed, high volume oil pump, electronic distributor, new water pump, alternator, P/S pump, Performer intake manifold and fuel injection is assembled to complete the new power plant.
Body work has begun
We know Bronco!!
Due to extensive damage to the original front inner clip, a good used inner core support assembly is found and will be fitted to the new tub
We removed the old inner front fender panels, cleaned mounting areas and refitted new inner fender panels. This is the easiest way we have found to install a front inner clip. Now the tub is complete again.
Our customer wants to use a new fuel injection system. This will require return fuel lines, high pressure pump etc..
Therefore we are going to replace the 11 gal aux tank and 13 gal main tank with one new 23 gal fuel injections main tank.
So we have decided to upgrade the body with a 1977 Bronco rear fuel tank filler door assembly
Door assembly is grafted into the rear quarter in the proper location and the old filler holes are filled in.
The tub is back from the blaster.
Some more minor body work is needed to ready for paint.
This page was last updated: June 30, 2011
Sheet metal work is complete and seams are sealed. Ready for paint.
Off to the body shop!! Sky Blue is in the future for this rig.
Back from paint and it is starting to look like it will live again!!
New multiport fuel injection system has been added to the engine for great drivability and performance.
New 23 gal rear fuel tank is installed.
All new stainless steel exhaust system w/Magnaflow turbo mufflers has been installed
The body tub gets a coating of urethane on the inside and underside to ensure it will not suffer rust issues in the future.
Stainless Steel brake lines, high pressure and return fuel lines are plumbed to the primary high pressure fuel pump and secondary pulse pump. New wiring harness is also installed for the rear of the body and the class 2 hitch we will be installing for the customer.
How SWEET is this? It is a Bronco again!!!
Let reassembly begin!!
We will start with the firewall.
New firewall pad is installed
New carpet kit is laid out for a few days to settle
The driver side airbox goes in this area
We are using stainless steel fasteners anywhere on the rig that is practical to prevent any rust
Heater air inlet duct is fitted to the right kickpan
The heater air inlet housing is installed
The heater unit is completely rebuilt and ready to install
We install the 1977 Bronco gas filler neck and door assembly
This turned out to be a very nice touch
New tinted windshield w/Sport trim is added
Little by little the Bronco is coming back to life!
We have rebuilt, stock, ginger houndstooth covered seats front and rear, matching door and inner rear quarter panels as well as a roll bar to be installed soon.
We are finishing up work on the dash, wiring, rebuilt steering column and pedal assemblies as well.
Tailgate and tire carrier using high quality stainless steel fasteners so that rust will not become an issue in the future
All new rubber bumpers and urethane hinges are used on the tailgate to eliminate rattling
Heater assembly is installed
Front fenders, grill and hood are final fit
The customer has requested that we run cord to pull speaker wires under the carpet for his sound system.
New belt line trim is added
Seats and rear panels are installed
The grill is back from paint and fully assembled
Roll bar and seats are bolted in
Seat belts and the white soft top are next
The small details will set this Bronco apart from all the rest.
It is coming together nicely.
Dash is ready to build
Dash is ready to install
Refurbished speedo cluster and switches, new defrost duct and hoses, new glove box, wiring harness has been rebuilt and integrated with the fuel injection harness.
Dash is installed with new custom dash pad. Fuel injection computer is installed up under the cowl behind the dash to protect it from any water
Engine compartment and fuel injection wiring is installed. New dry cell battery to eliminate the possibility of corrosion. New switches, senders and new or refurbed wiring harnesses.
Let there be light!!
New soft top is installed with zip out tinted windows.
The engine compartment is complete!!
302 V8 w/ MPFI
The interior is also complete!!
Bronco Project Is Complete!!
As luck would have it, we completed the project at the same time our local hot rod club held their annual mid winter car show. So we entered the rig to see how we would do.
We won the People Choice Award for the pickup division of the show!!
Into the Bronco hauler for delivery to another Happy Customer!!
