Steve83 > 1983 Ford Bronco > open folder Body Repairs

Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
Hits: 2162
Size: 88 KB
Posted: 9/14/08
Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...		Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
Hits: 1808
Size: 93.56 KB
Posted: 9/14/08
Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...		Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...
Hits: 1776
Size: 80.26 KB
Posted: 9/14/08
Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r...		Using state-of-the-art masking & paint booth technology, I put a few light coats of primer on.
Hits: 1807
Size: 85.08 KB
Posted: 9/14/08
Using state-of-the-art masking & paint booth technology, I put a few light coats of primer on.		After a few seconds, I put on the first topcoat.
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Size: 89.9 KB
Posted: 9/14/08
After a few seconds, I put on the first topcoat.
Then another topcoat.
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Size: 88.28 KB
Posted: 9/14/08
Then another topcoat.		After a few minutes, it looks OK. ...at least as good as the rest of the truck.
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Size: 96.31 KB
Posted: 9/14/08
After a few minutes, it looks OK. ...at least as good as the rest of the truck.		I picked this beauty up at a local junkyard for ~$30. What a steal!
Hits: 1707
Size: 83.87 KB
Posted: 9/14/08
I picked this beauty up at a local junkyard for ~$30. What a steal!		The used 120-grit pad wasn't cutting it, so I switched to a used 80-grit. When that started coming ...
Hits: 1678
Size: 89.17 KB
Posted: 9/14/08
The used 120-grit pad wasn't cutting it, so I switched to a used 80-grit. When that started coming ...		It took ~3/4 can of primer to get a few light coats on both sides & inside.
Hits: 1701
Size: 87.3 KB
Posted: 9/15/08
It took ~3/4 can of primer to get a few light coats on both sides & inside.
This isn't marketed for paint, but it's good enough for this truck.
Hits: 594
Size: 72.64 KB
Posted: 3/13/16
This isn't marketed for paint, but it's good enough for this truck.		I didn't expect show-quality from this, but I thought it might save some time.
Hits: 2113
Size: 102.64 KB
Posted: 9/15/08
I didn't expect show-quality from this, but I thought it might save some time.		It's actually a REALLY good-looking spatter finish. :) Too bad that's not what I want. :( **...
Hits: 2027
Size: 104.8 KB
Posted: 9/15/08
It's actually a REALLY good-looking spatter finish. :) Too bad that's not what I want. :( **...		After a failed attempt with the mighty Wagner HVLP deck stain gun on the inner face, I switched back...
Hits: 1781
Size: 83.54 KB
Posted: 9/15/08
After a failed attempt with the mighty Wagner HVLP deck stain gun on the inner face, I switched back...		It's building up slowly, and not as bad as I expected.
Hits: 1735
Size: 68.23 KB
Posted: 9/15/08
It's building up slowly, and not as bad as I expected.
I've emptied & pressure-washed this '95 door, and I'm about to sand it. The factory trim strip remo...
Hits: 1883
Size: 87.43 KB
Posted: 9/16/08
I've emptied & pressure-washed this '95 door, and I'm about to sand it. The factory trim strip remo...		The clearcoat is surprisingly tough - it stood up to the 80-grit sanding better than I thought it wo...
Hits: 1672
Size: 88.83 KB
Posted: 9/16/08
The clearcoat is surprisingly tough - it stood up to the 80-grit sanding better than I thought it wo...		Since this paint was in MUCH better condition than the fender, I only primed where I hit metal.
Hits: 1745
Size: 84.86 KB
Posted: 9/17/08
Since this paint was in MUCH better condition than the fender, I only primed where I hit metal.		Since this paint was in MUCH better condition than the fender, I only primed where I hit metal.
Hits: 1669
Size: 97.95 KB
Posted: 9/17/08
Since this paint was in MUCH better condition than the fender, I only primed where I hit metal.		The first LIGHT coat of paint.
Hits: 1722
Size: 48.82 KB
Posted: 9/17/08
The first LIGHT coat of paint.
The first LIGHT coat of paint.
Hits: 1644
Size: 95.94 KB
Posted: 9/17/08
The first LIGHT coat of paint.		Finished with the black. The light, hazy areas are reflections. I'll (probably) do the tan after i...
Hits: 1651
Size: 84.7 KB
Posted: 9/19/08
Finished with the black. The light, hazy areas are reflections. I'll (probably) do the tan after i...		Finished with the black. I'll (probably) do the tan after it & the fender are installed.
Hits: 1618
Size: 91.45 KB
Posted: 9/19/08
Finished with the black. I'll (probably) do the tan after it & the fender are installed.		The lower rear bolt (13mm) and the one in the door jamb (10mm) are out. With the hood supported, re...
Hits: 2024
Size: 65.08 KB
Posted: 9/20/08
The lower rear bolt (13mm) and the one in the door jamb (10mm) are out. With the hood supported, re...		First, I removed the battery, tray, starter relay, PA, coffee can, 2ndry air intake, & wheelwell for...
Hits: 1906
Size: 107.34 KB
Posted: 9/20/08
First, I removed the battery, tray, starter relay, PA, coffee can, 2ndry air intake, & wheelwell for...
With the wheelwell gone, the six 8mm (5/16") bolts at the front of the fender are much easier to acc...
Hits: 1682
Size: 69.88 KB
Posted: 9/20/08
With the wheelwell gone, the six 8mm (5/16") bolts at the front of the fender are much easier to acc...		The core support rotted out long ago, due to leaking batteries. But that section only holds the for...
Hits: 1767
Size: 106.28 KB
Posted: 9/20/08
The core support rotted out long ago, due to leaking batteries. But that section only holds the for...		The fender then comes off easily. While it's off, I'll fix the exhaust leak. But the original reas...
Hits: 3255
Size: 101.22 KB
Posted: 9/20/08
The fender then comes off easily. While it's off, I'll fix the exhaust leak. But the original reas...		The cardboard on the body horn is the shim for adjusting the height of the fender to the door body l...
Hits: 2286
Size: 92.04 KB
Posted: 9/20/08
The cardboard on the body horn is the shim for adjusting the height of the fender to the door body l...		This is the only reason I'm replacing the fender - the nuts for the battery tray ripped out years ag...
Hits: 1737
Size: 112.29 KB
Posted: 9/20/08
This is the only reason I'm replacing the fender - the nuts for the battery tray ripped out years ag...
With the fender removed, the hinge bolts are EASY to access. For door alignment, see this post: htt...
Hits: 2240
Size: 49.25 KB
Posted: 9/20/08
With the fender removed, the hinge bolts are EASY to access. For door alignment, see this post: htt...		The last time I worked on the hinges, the fender was in-place, and apparently, I forgot to tighten t...
Hits: 1867
Size: 83.19 KB
Posted: 9/20/08
The last time I worked on the hinges, the fender was in-place, and apparently, I forgot to tighten t...		The door has been emptied, and the wiring is loose inside it. It's ready to come off. For more abo...
Hits: 1717
Size: 93.79 KB
Posted: 9/20/08
The door has been emptied, and the wiring is loose inside it. It's ready to come off. For more abo...		The door has been emptied, and the wiring is loose inside it. It's ready to come off. This is an '...
Hits: 1731
Size: 100.42 KB
Posted: 9/20/08
The door has been emptied, and the wiring is loose inside it. It's ready to come off. This is an '...		The wiring connectors fit out the hole in the door, but the harness can also be unplugged from the p...
Hits: 1558
Size: 94.37 KB
Posted: 9/20/08
The wiring connectors fit out the hole in the door, but the harness can also be unplugged from the p...
The doors use captive nut plates for the hinge bolts. The body's hinge nut plates are similar, as a...
Hits: 2304
Size: 75.26 KB
Posted: 9/20/08
The doors use captive nut plates for the hinge bolts. The body's hinge nut plates are similar, as a...		The '92-96 door panels interfere with the '80-86 dash slightly, which is why the pad is dimpled & di...
Hits: 1622
Size: 73.32 KB
Posted: 9/20/08
The '92-96 door panels interfere with the '80-86 dash slightly, which is why the pad is dimpled & di...		I got the orange-peel almost PERFECTLY even. :D With the fender off, aligning the door will be VERY...
Hits: 1814
Size: 89.41 KB
Posted: 9/20/08
I got the orange-peel almost PERFECTLY even. :D With the fender off, aligning the door will be VERY...		This is just about where I want it. The weight of the internals should bring the door down just to ...
Hits: 2019
Size: 73.99 KB
Posted: 9/20/08
This is just about where I want it. The weight of the internals should bring the door down just to ...		The door doesn't fit the opening exactly right, but considering what the body has been through, it's...
Hits: 1867
Size: 73.64 KB
Posted: 9/20/08
The door doesn't fit the opening exactly right, but considering what the body has been through, it's...
After a little massaging, the door fits even better. For door alignment, see this post: http://www....
Hits: 1566
Size: 84.89 KB
Posted: 9/20/08
After a little massaging, the door fits even better. For door alignment, see this post: http://www....		It's barely visible, but there's a tapering gap between the door & body seal, indicating that THIS e...
Hits: 1584
Size: 45.24 KB
Posted: 9/20/08
It's barely visible, but there's a tapering gap between the door & body seal, indicating that THIS e...		I've re-adjusted the hinges so the lower front edge of the door seals evenly. To make the rear edge...
Hits: 1799
Size: 50.11 KB
Posted: 9/20/08
I've re-adjusted the hinges so the lower front edge of the door seals evenly. To make the rear edge...		To complete the alignment, the latch & strike must be installed. This later style of lock motor mus...
Hits: 1506
Size: 52.31 KB
Posted: 9/20/08
To complete the alignment, the latch & strike must be installed. This later style of lock motor mus...		The '95 door lines match the '82 body lines perfectly. There was actually NO change to the door lin...
Hits: 2240
Size: 95.68 KB
Posted: 9/20/08
The '95 door lines match the '82 body lines perfectly. There was actually NO change to the door lin...
PERFECTION!!!
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Size: 66.33 KB
Posted: 10/2/08
PERFECTION!!!		I got sick of seeing the all-black door & fender faster than I expected, so after hunting through ~5...
Hits: 1702
Size: 51.94 KB
Posted: 10/6/08
I got sick of seeing the all-black door & fender faster than I expected, so after hunting through ~5...		I didn't feel like painting the whole thing at once (& I couldn't find enough newspaper), so I just ...
Hits: 1646
Size: 65.6 KB
Posted: 10/6/08
I didn't feel like painting the whole thing at once (& I couldn't find enough newspaper), so I just ...		The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu...
Hits: 1584
Size: 66.81 KB
Posted: 10/6/08
The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu...		The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu...
Hits: 1682
Size: 69.27 KB
Posted: 10/6/08
The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu...
After a few minutes, I pulled the masking off.
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Size: 54.67 KB
Posted: 10/6/08
After a few minutes, I pulled the masking off.		Good enough for me!
Hits: 1780
Size: 65.97 KB
Posted: 10/6/08
Good enough for me!		Good enough for me! It'll be spread across the rocks & trees at the SuperLift park in Hot Springs s...
Hits: 1577
Size: 49.5 KB
Posted: 10/6/08
Good enough for me! It'll be spread across the rocks & trees at the SuperLift park in Hot Springs s...		For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a...
Hits: 1576
Size: 54.96 KB
Posted: 6/13/09
For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a...		For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a...
Hits: 1316
Size: 75.98 KB
Posted: 6/13/09
For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a...
The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...
Hits: 1599
Size: 80.56 KB
Posted: 6/13/09
The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...		This is the L outboard end of that body crossmember. It holds the bedrail upright & supports the qu...
Hits: 1438
Size: 78.56 KB
Posted: 6/13/09
This is the L outboard end of that body crossmember. It holds the bedrail upright & supports the qu...		The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...
Hits: 1471
Size: 74.66 KB
Posted: 6/13/09
The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...		This is the R outboard end of that body crossmember. It holds the bedrail upright & supports the qua...
Hits: 1459
Size: 81.18 KB
Posted: 6/13/09
This is the R outboard end of that body crossmember. It holds the bedrail upright & supports the qua...		Before the frame shop worked on it, I couldn't get the t/g this far open (which still isn't all the ...
Hits: 1503
Size: 60.48 KB
Posted: 6/13/09
Before the frame shop worked on it, I couldn't get the t/g this far open (which still isn't all the ...
The main bend in the body crossmember is close to the R body mount, where the visible kink is.
Hits: 1493
Size: 36.79 KB
Posted: 6/13/09
The main bend in the body crossmember is close to the R body mount, where the visible kink is.		To repair it, I'm going to use this I-beam (because I have it), but it has to be the right length. ...
Hits: 1511
Size: 68.09 KB
Posted: 6/13/09
To repair it, I'm going to use this I-beam (because I have it), but it has to be the right length. ...		The hooks on this ratcheting cargo strap fit perfectly, and the body crossmember is strong enough to...
Hits: 1490
Size: 47.97 KB
Posted: 6/13/09
The hooks on this ratcheting cargo strap fit perfectly, and the body crossmember is strong enough to...		I laid the long beam across the bedrails & put my heaviest ratchet strap over it. The strap is just ...
Hits: 1568
Size: 56.97 KB
Posted: 6/13/09
I laid the long beam across the bedrails & put my heaviest ratchet strap over it. The strap is just ...		As tension rises in the strap, there's a lot of groaning. The short beam is directly above the kink...
Hits: 2003
Size: 64.83 KB
Posted: 6/13/09
As tension rises in the strap, there's a lot of groaning. The short beam is directly above the kink...
The strap started off just snug, so it's stretching noticeably. The rags are being cut by the immen...
Hits: 1573
Size: 64.14 KB
Posted: 6/13/09
The strap started off just snug, so it's stretching noticeably. The rags are being cut by the immen...		Yes, the beam is bending, too. And there's a real risk of the jack shooting out from under the beam...
Hits: 1545
Size: 59.03 KB
Posted: 6/13/09
Yes, the beam is bending, too. And there's a real risk of the jack shooting out from under the beam...		But the body is bending the way I planned, so it's working. For the first time in 5 years, the cabl...
Hits: 1408
Size: 80.12 KB
Posted: 6/13/09
But the body is bending the way I planned, so it's working. For the first time in 5 years, the cabl...		Despite the progress I made with the first pull, I decided to reset & use another jack. This time, ...
Hits: 1643
Size: 65.01 KB
Posted: 6/13/09
Despite the progress I made with the first pull, I decided to reset & use another jack. This time, ...		I was surprised at how easily I was able to bend this 48" Gorilla Bar. Maybe it wasn't designe...
Hits: 1443
Size: 76.44 KB
Posted: 6/13/09
I was surprised at how easily I was able to bend this 48" Gorilla Bar. Maybe it wasn't designe...
This isn't making as much visible progress as the first pull, and I eventually put so much pressure ...
Hits: 1534
Size: 74.82 KB
Posted: 6/13/09
This isn't making as much visible progress as the first pull, and I eventually put so much pressure ...		After the explosion, I reset the cribbing & put a laminated wood board under the short beam to allow...
Hits: 1475
Size: 62.54 KB
Posted: 6/13/09
After the explosion, I reset the cribbing & put a laminated wood board under the short beam to allow...		The rubber pad on the bumper lid is now barely touching the t/g trim panel, just like when I install...
Hits: 1434
Size: 78.74 KB
Posted: 6/13/09
The rubber pad on the bumper lid is now barely touching the t/g trim panel, just like when I install...		It's not visible, but the rubber pad on the bumper lid is now barely touching the t/g trim panel, ju...
Hits: 1406
Size: 55.65 KB
Posted: 6/13/09
It's not visible, but the rubber pad on the bumper lid is now barely touching the t/g trim panel, ju...		The apparent change is 1/2" on the L & 1" on the R.
Hits: 1381
Size: 43.48 KB
Posted: 6/13/09
The apparent change is 1/2" on the L & 1" on the R.
A vast improvement.
Hits: 1542
Size: 88.23 KB
Posted: 6/13/09
A vast improvement.		It's obviously better, though not quite as flat as I had hoped. But the gap between the t/g & bumpe...
Hits: 1626
Size: 61.2 KB
Posted: 6/13/09
It's obviously better, though not quite as flat as I had hoped. But the gap between the t/g & bumpe...		   
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