11/28 Christmas Tree Run
Truck run leaving Dayton fairgrounds at 10 am Tucannon/Camp Wootton
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1977 Bronco

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tobyw
Posts: 1983
Joined: Wed Mar 14, 2007 10:00 am
Location: Under the hood...

1977 Bronco

Postby tobyw » Tue Mar 04, 2025 10:57 am

You may have heard me say it before... I love Jeeps, but my true passion lies with the Bronco. And this is why:

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This handful of photographs is a snippet of the reality of my childhood, bouncing around in the back seat of a 1977 Ford Bronco in the mountains of Colorado. That's me, the tubby one standing in the middle looking at the masterpiece my old man had created for an overnight camping trip somewhere high in the Rockies circa 1980 or so 8)

Over the years, that Bronco served as the daily driver, hunting rig, and wheeler for our family. Sometime in the late 80's, my dad decided the Bronco was getting a little rough around the edges and retired it to wheeler/hunting only status and made the grave mistake of letting my older brother drive it to high school. After two separate rollover incidents, he yanked the keys from my brother, sent the Bronco back to the body shop, and generally continued to use it for recreational purposes only. All the while, poor little me was made painfully aware that, thanks to my older brother's shennanigans, I'd never get to drive it :cry: Fast forward a few years, still bouncing around the mountains of Colorado, but I now had my own set of wheels; my beloved 1947 Willys:

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This picture, circa 1994, shows the dark charcoal repaint on the Bronco from it's original seafoam green, albeit aged by several years and wearing some battle scars from your average Sunday drives to church and whatnot :lol: As the years wore on, the Bronco continued to see regular beatings, errrrr use, but started seeing less regular maintenance and repairs. I'd moved to Arizona and would only catch a glimpse of the poor Bronco here and there, and actually built a replica of my very own based on all of those romantic memories from my childhood, accurate right down to the PNW sticker in the side window:

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During the aftermath of Thanksgiving 2018, I decided it was time to do a little refresh on the ol' Bronc as a favor to my old man. I took stock of the situation, laid out some basic plans, and got the keys for the first time in my life:

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Game on :thu:
Yep, I've wheeled one of those, too...
Image

User avatar
tobyw
Posts: 1983
Joined: Wed Mar 14, 2007 10:00 am
Location: Under the hood...

Re: 1977 Bronco

Postby tobyw » Tue Mar 04, 2025 11:11 am

The first order of business was the get the Bronco up to my shop where I could work on it with some regularity. Trips down to the ranch in Oregon were few and far between, and simply not conducive to a concourse quality restoration such as I was about to embark on :roll: The tractor was commissioned to tug the non-running Bronco onto my trailer, and I then hauled it up to my place:

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My boy got the honors of piloting the sacred beast off the trailer and into the shop:

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The next thing I knew, a full-blown teardown ensued:

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With the body separated from the chassis, I stored it on my little flatbed trailer beside the shop and started concentrating my efforts on the mechanicals:

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:thu:
Yep, I've wheeled one of those, too...

Image

User avatar
tobyw
Posts: 1983
Joined: Wed Mar 14, 2007 10:00 am
Location: Under the hood...

Re: 1977 Bronco

Postby tobyw » Tue Mar 04, 2025 11:31 am

We pulled the drivetrain out after a good steam cleaning to knock the biggest of the chunks off:

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Then we tore the motor down, continuing to clean it up and inspect the years of field repairs and shocking over-use of RTV :shock:

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While this was going on, I had the chassis sand blasted by the mobile blasting outfit. While it was handy not having to haul the chassis somewhere to have it done, the mess left behind was less than ideal:

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I slapped on some primer and paint:

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With the chassis rails tidied back up, new rear leaf springs, shackles, and front suspension bushings were installed and then the refreshed drivetrain was slapped back in:

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:thu:
Yep, I've wheeled one of those, too...

Image

User avatar
tobyw
Posts: 1983
Joined: Wed Mar 14, 2007 10:00 am
Location: Under the hood...

Re: 1977 Bronco

Postby tobyw » Tue Mar 04, 2025 12:34 pm

Just for some additional background on the Bronco itself, my old man purchased it brand new from a dealer in Spokane. It was one of the last ones available in the Northwest, and it's a Ranger edition which netted you things like chrome window moldings and the houndstooth interior 8) Over the years the little 302cid engine was rebuilt including a balance and blueprint job, the C4 transmission was rebuilt (twice), and the Dana 20 transfercase was upgraded with a twin stick shifter arrangement. The front Dana 44 received chromoly shafts, 4.56 gears, and a Lock-Rite lunchbox locker as well as drive slugs to replace the locking hubs. Out back, the Ford 9inch was treated to a Currie 4.56/Detroit third member and Currie 31-spline chromoly shafts. Both front and rear driveshafts came from Tom Woods. Overall, a very durable and potent little package for trail use 8)

All of that is really to clarify that, my goal in this endeavor was never to make the Bronco "nice" again, but rather to get it back into mechanically sound condition and keep it on the trails. The bones are good, and I'm not even remotely interested in body work or the heartache that comes with having to make the tough decision between a rock or a tree after having spent good money on any sort of body work... She's a wheeler, and always will be.

:thu:
Yep, I've wheeled one of those, too...

Image

User avatar
tobyw
Posts: 1983
Joined: Wed Mar 14, 2007 10:00 am
Location: Under the hood...

Re: 1977 Bronco

Postby tobyw » Tue Mar 04, 2025 12:59 pm

With the freshened up drivetrain back on location, I started routing the exhaust and some of the main runs of plumbing down the frame rails:

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After popping in fresh body mounts, it was time to marry the body back to the chassis after nearly 2 years of separation:

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Next up was the wiring, for which I turnt to Painless Performance and their complete rewire kit specific to the early Bronco. Although the name would have you thinking otherwise, there is nothing "painless" about this process :oops:

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Believe it or not, in the 40+ years this thing has been around, the hard top had never previously been off... It was high time to make that happen:

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Next, I pulled the cage my dad had built back in 1978...

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...and proceeded to start fabricating one for myself:

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Going for the full retro vibe, the cage just had to be white:

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Soon enough, I had cobbled together enough of the mechanical bits and wiring to fire it up and actually drive it for the first time since 2015 or so when it was put out to pasture:

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:thu:
Yep, I've wheeled one of those, too...

Image

User avatar
tobyw
Posts: 1983
Joined: Wed Mar 14, 2007 10:00 am
Location: Under the hood...

Re: 1977 Bronco

Postby tobyw » Tue Mar 04, 2025 1:22 pm

With it now running and driving again, sort of at least, it was time to start concentrating on the funner side of things. For me, that's fabrication 8) Years ago, we had cut out the badly damaged rockers and replaced them with box tubing. I used these as a foundation to glue on some outriggers in an effort to keep rocks and trees a little further way from the sheetmetal in the future:

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At the same time, I mocked up a new set of fender flares. Nothing can make or break the aesthetic of an early Bronco quite like the flares, and although I'm not in love with this particular set, they are just good enough to stay out of the trash bin. For now at least...

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With things starting to take visual shape, it was time to concentrate on the rear bumper and finish out the exhaust. Now, these two things might seem mutually exclusive, but I had an idea... As with most rigs of this nature, the exhaust typically exits behind the rear tires and below the body/bumper, leaving it very exposed and often getting crushed in the church parking lot :lol: To alleviate this, I wanted the exhaust to run through the rear bumper 8) To say this took some canoitering would be a gross understatement, but I managed to make it happen:

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This was then all finished off with more of the requisite retro white paint:

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:thu:
Yep, I've wheeled one of those, too...

Image

User avatar
tobyw
Posts: 1983
Joined: Wed Mar 14, 2007 10:00 am
Location: Under the hood...

Re: 1977 Bronco

Postby tobyw » Tue Mar 04, 2025 1:42 pm

As noted prior, the Bronco will never be pretty, and I don't want it to be. With that said, I do have my standards :lol: Some new carpet was added to the interior:

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We spent about a year just enjoying the Bronco as it was, using it for ice cream runs, running to the fuel station for lawn mower gas, and for shuttling trailers around the yard and whatnot:

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My old man was over the moon with what I'd done, but there was something making my eye twitch... the damn rollcage. Much to my dismay, the C-pillars had drawn inward pretty dramatically when I finish welded it, and it's 100% my fault for not properly immobilizing it while gluing it all together :x I just could not stand the look from the rear of the thing, and after some internal debate I finally made the decision to cut it out and start over:

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I changed up the overall design pretty significantly, and this time it fits the body lines a lot tighter and is much simpler. I'm so much happier with how it looks at this point:

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So that pretty much brings things up to current, covering progress over the past 5-years :shock: :roll: :oops: In my defense, there have been countless other projects rolling through the shop throughout this timeframe, but that's really no excuse as this all could have been done in a long weekend :lol: :|

Going forward, I need to rebuild the front bumper, address the tire and wheel situation, and just use it more. It may get some paint thrown at it just so it's all one color again, but trust me when I tell you that any paint will be of shockingly low quality sprayed directly over what's already there :thu:
Yep, I've wheeled one of those, too...

Image


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