Happy Day

I finished the wiring - well mostly, still tracking down a few gremlins.

I don't yet have the radiator installed - but I desperately wanted to fire up the engine.  The wiring is good to the best of my knowledge, considering the harness is fairly universal to fit every combination of components.  From the different types of alternators to starters.  I of course chose the simplest combo being a 1 wire alternator and 1 wire starter and MSD ignition system.  Took a bit to figure which wires go where and which I didn't need.

moment of truth - turned the key and ..... nothing.  So I went and mowed the lawn to sort it out in my head.  I know the MSD works because we used it at the dyno, then I sent it in for warranty issue, it came back with a clean bill of health.  Since I didn't have any clicks or anything, that meant the starter wasn't engaging.  I had two choices for the ignition wire to the starter solenoid.  And, there was another loop I removed for the neutral starter switch (which my transmission doesn't have).  I checked the starter switch wire and yes, there was momentary power when the key was turned.  I wired them together, pulled the coil wire, and yes - the starter engaged - I did this for a few minutes to prime everything.  Attached the coil wire and VAVOOM!  Started right up.

My new ride

First I wanted a Datsun Roadster like this

These are the original Z cars built in the 60's until 1970.  I can get one of these for under $10K.  The problem is that they are 40+ years old and the ones I looked at need as much work as the Bronco.  One project at a time.

Then I realized that a modern car is needed for a daily driver.

So I next looked at the Ford Raptor like this

In fact - I drove this very one.  LOVED IT.  I just couldn't get the dealership to agree to the price I wanted to pay.  These beasts are very cool, but the gas prices are driving the buyers away.  The dealer saw it otherwise.  I shopped around the country and found a few others for the price I wanted, but either the travel or the shipping would put it back above what I wanted to shell out.

And I am already building a loud, gas guzzling, 4x4.  Don't need 2.

The wife saw this Volvo P1800 at a local vintage car dealer

And although it is very cool in a James Bond kind of way - it's the 40 year old daily driver syndrome again.  Perhaps as my next project when the Bronco is done.

I settled on this 2010 Audi A4 Quattro

4 cylinder 2.0L Turbo.  Practicality won out, but I did it with style.  6 speed manual transmission and a whole lot of torque.

March started with a bang

Really - I crashed my Acura and it has been deemed totaled.

Really?  I had this car for 10 years, and it was always fun to dream of something else, but reality sucks that I have to actually do it.  So manyy option.

Started working on the wiring harness - and put the full dash together.

And then -

Body, meet frame.  And the two were one!!

See my cool aluminum slots there?  I got to get them polished up.

February was spent installing the twin stick setup for the transfer case, installing the hydroboost brake system and power steering.  Much time spent getting the ps pump pulley lined up with the crankshaft, new bracket later and many shims and success.

Before I forget - somewhere in there I reworked the pedal assembly and figured out the master cylinder hookup for the hydraulic clutch.  Rebuilt the heater box, and passenger side air vent and a bunch of other stuff I don't remember because too much time has gone by.

Let's get up to date

Most of January was spent installing the 5 speed NV3550 transmission.  This included some modification to the bell housing.  So it goes 351W engine, Ford Bellhousing, adaptor, Jeep transmission, adaptor, Ford Dana 20 transfer case.

Got both front and rear driveshafts rebuilt and painted by a local shop.

Now I created a new problem - that being that the mechanical clutch assembly doesn't clear the header pipes.

Look at that crazy angle.  No amount of shimming or reseat of the engine mounts or twisting of the engine would make this go away.  

So after much research, I chose to convert to a hydraulic setup.  Which is probably better anyway considering the 11 finger clutch pressure plate that is in there now.  I had to bring my budding welding skills to the forefront and design/build a bracket for the slave cylinder.  Success!!!

????

No I am not dead - just lazy

Anniversary

One year into the madness!!

When I embarked on this project – I had read, and been told to expect to spend 3-5 years on a total rebuild.  1 year later – I think I can be mostly done by summer.  But I am quite sure these projects are never truly done.

After finishing the front end, I started on the rear and got stopped fast by the disk brake setup.  All of the vendors are great at providing kits and custom parts made to fit Bronco’s – but very few come with good instructions.  They all have this assumption that I know what I’m doing, or have done it 5 times already.  Luckily there are some great Bronco forums out there with hundreds of people in the same boat, as well as hundreds more that have already done what I am doing – even down to the exact same parts.  Advice to vendors – more pictures on your instructions.

Anyway – I upgraded my rear axles from 28 spline to 31 spline.  This means that my small bearing housing now has a big bearing axle.  Finding the axle seal was quite a challenge, and it is now going on 2 weeks of backorder.  

With nothing else going on – I started shopping again for more of the “little detail” parts, like a bumper for the tire latch, the stainless cover for the tire carrier where the latch connects…..  getting way carried away, what the heck am I building anyway?

The body is home from the bodyshop and parts are all over the house, (to protect them of course) since I cannot put them onto the main body until it is on the frame.  Doors, grill, tailgate in my office, hood in the bathroom….  The wife is VERY understanding considering it has been about 3 months since her car has been in the garage.  This has cost me custom cabinetry for her craft room, new luggage, an Ipad… you get the idea.