1969 FS Bronco

[FordTruck]

this project is so freakin......AWSOME!!!

[trukcrazy]

That is looking incredible. I'll take one please.....

[Calfdemon]

This is coming out amazing!! Truly a one of a kind "Bumpco"!!

[dolinick]

this project is so freakin......AWSOME!!!

[lowridingf250]

That is looking incredible. I'll take one please.....

Just one?

[Joshpow]

Looking good. Keep us posted. I think were in for a cool finished project in the near future!!

[dolinick]

The first one is always the hardest right? We can all make a bump bronco now and take over the world!

oh, wait I ought to let him finish this one first.

[Fordnatic]

How's it coming? I'm itching for an update!

[bnl44]

I needed a cross section of the bed to be able to see where things would line up.
I just happen to have a some left over to help out with this.


This part was actually done before the last post.
Not that I am trying to write a tutorial. I thought some of you would like to see some of the challenges that come up.
Here is a match up to the rear pillar.

A slot is needed in this area. It leaves a little for height adjustment in the rear.

Slot made. The excess space will be filled with metal section or weld.


I couldn’t believe how heavy the bed end cap was, so I put it on a scale, 13 pounds!
Now that’s some “real metal”.



Marked for trimming.


Here you can see how the Bronco end cap is mostly flush with the jamb. And the pickup end cap has the jamb recessed 3/8” for tailgate hardware. As the contour around the tail light and the body lines different, I need to move the jamb closer to the edge.


After drilling out the spot welds and trimming down to a minimum piece. The jamb pieces will be swapped left side to right side and right side to left, recessed only the thickness of the Bronco jamb piece and plug welded in on the back side.



Next, the bottom of the rear corner pillar is totally interfering with the shorter pickup end caps.

[forrestbump]

I am absolutely amazed at your talent, attention to detail, thought processing and speed at which your project is traversing to completion. I am in awe of your work on this project!

[Joshpow]

Lets see those cpas on!! Looking great. Cant wait to see some finished pics.

[hotrod ford]

WOW, that is awsome. Great Job!

[bnl44]

This picture shows how the bedside matches up to the rear pillar. The pillar is too low.

Here you can see how the vertical joint of the end cap is interfered by the rear pillar.

You can see how this pocket will fill up with mud and debris and cause a rust pocket. Notice the bottom of the pillar cut off.

The bottom has already been trimmed off but more modification is necessary.

A little trimming.

A little reforming.

Weld to the rear sill panel. Strength retained, more clearance gained and no more pocket to trap debris.

[bnl44]

The front needs to be sucked in a little more. Modifying where the inner bed panel meets up with the front reinforcement pillar.


The correct wheel house in place.

Remember that little 1/8” hole drilled in the wheel house for center line reference.
Here it is lined up with center line marked on the Bronco floor.

Cab corner flanged for tighter fit.

Here is a new issue. The upper bed portion has a greater curve than the door and end cap.

Relief cut to keep as much of the rear pillar’s strength in tact.

Notice all the holes from drilling out spot welds.
- Upper bed side has that greater curve than the end cap also, same as the front.
- The upper portion of the bump, next to the seam sticks out further than the shape on the end cap.
- How close the center line of the bump lines up to the tape reference line.
- The tailgate body lines are a little too far apart.
- The new decal on my yellow tool box in the back ground.

Bed cap in place.

A few screws.


So…. What do you think?



Now I just have to repeat for the left side.

[67bartcat]

Looks Great. I envy your skill. That Bronco is going to look Factory Built.