Going Redneck

I figure that somewhere in this project I will need to join metal to metal.  Be it replacing rusted out panels, crafting brackets, filling the odd hole here and there... and I can't keep paying some traveling welder dude.

So I aquired... da, da, da, da....

My very own MIG welder.  Never did any welding in my life, but I am sure to be popular in my neighborhood once they find out I have one.  But maybe not if I can't figure it out.  The internet is full of tips and dos and donts so this should be a hoot.

Premature Parts

I've barely started, but I couldn't resist ordering some parts.  And I experienced my first disappointment. 

When I took the hardtop off, I went ahead and started to disassemble what I could and begin my documentation process to help put it back together.  I grabbed the digital camera and took a gazillion pictures - I won't post them here because they simply aren't very interesting - just pictures of lots of flaked paint and worn parts to be used as reference points come reassembly time.

Anyway - as I was struggling with the hardtop lift handle, I decided to order some replacements in the form of gaskets and a new handle - because as you can see below, the original is seemingly stripped as it simply spun instead of opening the lift

First let me say that the list of aftermarket, OEM, and NOS suppliers for early Broncos is astonishingly long.  I went with Tom's Bronco Parts in OR for my maiden purchase as he has not one, but two lift handles to choose from; the $15 aftermarket and the recommended high quality handle for $10 more - of course I went for the high quality.

Boxes arrived and this is when I had my first disappointment

The handle on top is the "High Quality" replacement, and it is solid and heavy and would certainly do the job for a long time - however, when compared to the original on the bottom, it doesn't even come close to the quality of the American Made original.  The original just feels good - and right - and who am I to replace this thing of beauty, form and function?  And furthermore - the HQ replacement had the same key code as the one pictured in the catalog leading me to believe that anyone with this replacement handle would have a key to my Bronco.  What to do...

I took another hard look at the original - could I weld some material onto the square nub and file it back to shape?  How can I get the lock cylinder out so that it can be rechromed?  Well the first part of the question turned out to be an easy answer - I had also ordered a new spider gear, the mechanism inside the lift that the handle actuates and as it turns out, the new one holds the answer - it will be a very tight fit onto the square nub unlike the stressed wobbly one I pulled off, thus negating the need to worry about the wear pattern on the original - hooray!

Now to find an automotive locksmith to get that lock cylinder removed

Step One

So I figure I should start by removing the hardtop.  My internet research has told me that it weighs between 150 and 200 lbs and that one person "could" turtle walk it off.  Or 3-4 guys could easily lift it off.   Since I ultimately don't have a place to store it at ground level, and am blessed with 12' garage ceilings, I figure a hoist system would allow easy removal and storage to boot.

I checked several online hoist sites including the Harken Hoister but figured I could do it myself with some Home Depot Pulleys and a boat winch from Harbor Freight for much less.

This is what I came up with.

 

Using polypropelene rope coming to a central gather point that is hooked to the boat winch with 25' of cable

This worked great and I even found that I could remove the handle from the winch and use my drill to engage the worm drive.  Here is the Hardtop all snug and warm.

Now the sharp eyed individual would immediately notice that the blue Polypro rope is now red.  Let me explain; it would seem that I failed to account for the stretch factor of the rope and it only took a single day before the garage door crashed into the hardtop.  Quick run to HD and purchase of red vinyl wrapped 1/8 cable conveniently packaged as a dog run and I'm back in business.

So it begins

My first Blog - and first post - Since I am starting a restoration, it would be fun to document what I do for others in the same situation, and for myself when it comes time to put this thing back together.

Task #1 - aquire a Bronco.  Complete.

I found this 1969 beauty on Craigslist and it met all of my requirements - not a lot of rust and minimal prior restoration work.  The previous owner had already upgraded the front end with Dana 44/disc brakes... so, one le$$ thing.

He threw in a couple of Chilton manuals and a box of "Bronco Driver" magazines back to issue #1 (these have proved to be a wealth of information)

My buddy drove to inspect it, and I drove it home - 3 speed manual on the column was interesting to figure out - but I didn't stall and got it home in one piece where it now lives in the garage.  I wanted the bigger half of the garage that The Wife occupied with our Toyota Sequoia - and it of course would not fit on the other side because of some shelving on the back wall - so the Toyota had to go since there was no way she would park in the driveway.

I have now owned the Bronco for 3 weeks as I peruse the magazines and start my list of what I want to end up with and of course how to tackle the project.  Since I finally decided on a complete "frame-off mostly do-it-myself with willing assistance from my son" restoration, I come to the realization that this could take some time and ca$h to accomplish.  What fun!