Brakes are now mostly wrapped up. No p-brake cables yet (on the way), and not doing anything up front until I do the disc conversion, but not in a hurry on that.
Installed the second front spring, I'm now going to call it about 3" to 3½" suspension lift on both ends. Then adjusted and installed the new track bar. Got the axle centered to the frame within about ⅛". Looks like the uncut fender clearance will be fine with the 7" wide wheels and 31x10.50 tires. New shocks will arrive soon.
Hung the right door and fender, and then the grill. Fit seems reasonable so far, other than the bottom front of the 2 fenders tucking a bit sharper underneath. Will need some massaging to make them match the grill.
Gathering info and testing parts in preparation for the complete rewiring of the truck. A few more parts (mostly replacement switches) are also on the way.
New milestone today. Read on.
Since the post above, three new p-brake cables have been installed. Which means the brakes are all new except for the upcoming front disc conversion. Later this spring, I'm guessing.
Four new shocks have also been installed, so the suspension is mostly done.
Finally, the last few days have seen the beginning of the complete re-wiring project using the wiring harness kit I picked up a while back. But here's the new bit—today I actually started the engine using the key in the original ignition switch! No more hacked or McGivered wiring and switches needed. and since I replaced both the alternator (slightly upgraded) and the regulator (external solid-state) while doing the wiring, I've confirmed that it is delivering a nice, stable ~14.4v to the battery.
Lots more wiring yet to do. Stay tuned.
Been a while since I've updated you all here. (I post a lot more regularly on the Bronco forum.) Since the last post, the wiring is complete and tested, except for the wipers and heater blower, neither of which are installed now. I found a couple issues with the gauges, but should have that handled soon.
Completely replaced the fuel system as well—both tanks, hard and soft lines, selector switch (now electric), and rebuilt a slightly newer carb with auto-choke. Starts and runs much better now.
Next up will be to strip the engine for re-seal, all gaskets and seals, new water pump, check the timing chain, yada, yada, yada...
Spent the past couple of days stripping the engine. Dropped the pan, pulled the water pump and timing cover, and started assessing it all.
First thing I found is that the engine is not a 302. Crank casting mark is 1M, which is the 289 crank. Frankly, that's not a big deal in my opinion, not much difference between a bone-stock 289 and similar 302. About the only difference this will make is that I won't drill the new fenders and install new 302 badges.
Water pump was installed by someone who was... shall we say, generous with RTV. Yuck. And everything is seriously grimy, much cleaning will be required.
Found a couple of issues, none major since I found them now. Distributor shaft has more play than I like, the balancer has a noticeable groove worn where the seal rides, and the timing chain is about as loose and sloppy as I've ever seen.
I'm putting together a big parts order now. Included will be timing chain and both sprockets, water pump, Speedi-sleeve for the balancer, complete DuraSpark package, and all the normal stuff—many gaskets, t-stat and housing, plugs, molded hoses, gauge senders, heater core and valve, etc.
Lots of cleaning and painting will start tomorrow. Parts probably won't all be here for a week or so.
Progress has been made. (Although I haven't got the pan back on it yet...)
I tore the engine apart for resealing and deferred maintenance on or about 10 April. Here's what has transpired since then:
- Cleaned prior years of oil leak grunge.
- Replaced gaskets and seals - oil pan, valve covers, intake manifold, etc.
- Replaced timing chain and gears.
- Replaced water pump, t-stat, t-stat housing, etc.
- Replaced temp and oil senders.
- Converted to Duraspark II ignition.
- Painted various engine externals.
- Full power steering conversion - OER box, Saginaw pump, etc.
- Rebuilt steering column, incl. smooth collar (floor shift installed decades ago).
- Replaced radiator, hoses and mounts.
So, giving everything a last check, I re-connected the battery and turned the key. Took a few revs to fill the float bowl, but then it started up with little-to-no drama. Timing was close enough, and obviously I got the Duraspark wired correctly. One lifter was pretty clicky for a bit, but has quieted back down after a few minutes runtime. After pumping the oil all around, it was almost a quart low. Steering pump was pretty noisy until I ran the wheel back and forth a few times, now it's totally quiet and works great. No leaks anywhere so far. Looks like a successful refresh at this point. The next day I backed it out of the garage to get it completely warmed up, add some oil, and check the coolant level after the thermostat opened fully.
Now I can move on to another part of the project. Not quite sure what I'll do next.
Builds like this provide me with two things:
1. Nostalgia: when I was in middle school and then high school these were already 12-15 years old. They were all over the place and always such a cool alternative to a Jeep. A friend ran a small lawn mowing business and saved every dime for 3 years or so to buy one in beautiful shape. 40 years later he still owns it and it remains an amazing time capsule.
2. Awe at your skill level and commitment: I haven't the skill nor the commitment to dig into a project of this magnitude but I can live vicariously through these builds. I learn a little from each one I follow.
Yours in particular is really impressive and no doubt all of the documentation of the work completed will assist when it's time to sell it on. I dont know the market for these too well but I am guessing it will be quite valuable.
I hope you are chronicalling all of this on YouTube. Not only would I watch it but with the work you do I'm sure there is a good income opportunity there for you. Carry on!
No, nothing on youtube. I can't be bothered to video while I work. Heck, most of the time I'm lucky to remember to take pictures at all!
