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The "Coal Burner" Bronco

  #11  
Old 03-02-2016, 02:59 PM
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so with the engine in good shape I felt more comfortable in taking the plunge so it was time to cut the frame and figure out how this thing was gonna fit. I had to torch off the stock motor mount towers before I could even drop the engine in so i did that first.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1932_zps6821b68c.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1932_zps6821b68c.jpg" border="0" alt=" photo IMG_1932_zps6821b68c.jpg"/></a>

I dropped the engine in and quickly realized that the starter was gonna be a problem. So i hooked up the adapter plate and marked the frame where it hit. I cut a small hole first so i could get the engine in approx where i wanted it and to see if that was gonna work.

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1937_zps904f73eb.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1937_zps904f73eb.jpg" border="0" alt=" photo IMG_1937_zps904f73eb.jpg"/></a>

Once I was happy with the spot I cut the rest of the frame out to clear the starter.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1938_zps4305a186.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1938_zps4305a186.jpg" border="0" alt=" photo IMG_1938_zps4305a186.jpg"/></a>

Here it is all welded up. I know Im not a super fabricator but I think it turned out ok.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_3271_zpsa27da2c7.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_3271_zpsa27da2c7.jpg" border="0" alt=" photo IMG_3271_zpsa27da2c7.jpg"/></a>
 
  #12  
Old 03-15-2016, 07:14 PM
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Default Cutting the bronco frame to fit the 4BT

So the biggest hurdle for me was making the commitment to actually do this and torching off the engine mount towers was the turning point. So here they go
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1932_zps6821b68c.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1932_zps6821b68c.jpg" border="0" alt=" photo IMG_1932_zps6821b68c.jpg"/></a>
With the towers out I tried setting the engine in with the adapter and quickly realized that I was gonna have to cut a lot of the frame away for the starter.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1935_zpsc9985671.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1935_zpsc9985671.jpg" border="0" alt=" photo IMG_1935_zpsc9985671.jpg"/></a>

I started with a small hole to make sure I had it right and then went for the rest of it.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1936_zps52e08db7.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1936_zps52e08db7.jpg" border="0" alt=" photo IMG_1936_zps52e08db7.jpg"/></a>

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1937_zps904f73eb.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1937_zps904f73eb.jpg" border="0" alt=" photo IMG_1937_zps904f73eb.jpg"/></a>

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1938_zps4305a186.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1938_zps4305a186.jpg" border="0" alt=" photo IMG_1938_zps4305a186.jpg"/></a>

Here it is all welded up and looking as good as I could make it.

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_3271_zpsa27da2c7.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_3271_zpsa27da2c7.jpg" border="0" alt=" photo IMG_3271_zpsa27da2c7.jpg"/></a>
 
  #13  
Old 03-17-2016, 07:57 PM
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Default Cutting the Bronco front cross member

So with the frame cut I thought I would be able to get the engine in all the way but I wanted it lower so I cut the front cross member. Instead of just cutting off and replacing the whole thing, which probably would have been easier I decided to modify it to make it work. It was made with a top and bottom and then boxed and welded so I cut a section of the top half off then trimmed the lower part down. Then I set the top section back on. That allowed me to maintain the stock holes for the steering stabilizer shock.
Heres a view from the bottom
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_4594_zps44d36a77.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_4594_zps44d36a77.jpg" border="0" alt=" photo IMG_4594_zps44d36a77.jpg"/></a>
And from the top
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_3269_zps96f3b85e.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_3269_zps96f3b85e.jpg" border="0" alt=" photo IMG_3269_zps96f3b85e.jpg"/></a>
 
  #14  
Old 03-29-2016, 11:51 PM
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So I went to Moab last week! I only got one picture but gotta say it was the scariest pic I've ever taken. If there are any Bruiser Diesel Jeep guys on here that were on the trail with me I just want to say thanks for letting me tag along!
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/The%20Coal%20Burner%20Bronco%20in%20Moab_zpsbpglze 48.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/The%20Coal%20Burner%20Bronco%20in%20Moab_zpsbpglze 48.jpg" border="0" alt=" photo The Coal Burner Bronco in Moab_zpsbpglze48.jpg"/></a>
 
  #15  
Old 03-29-2016, 11:52 PM
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Also while I was gone I got my new Ron Francis Wiring Harness! I've been pretty cranky about my rats nest underneath the dash and Im pretty excited to get it fixed. I did a lot of research and Im hoping that because the harness isnt pre taped and bundled to where you only get to put it where they've decided it should go, that I will be able to really tuck the wires up nice and clean. Even more important though is that I will be able to tap directly into the fuse panel instead of splicing into the harness somewhere which created my whole rats nest in the first place. Hopefully one of these days soon I can get on it.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/Ron%20Francis%20Wiring%20Harness%20Early%20Bronco_ zpszxi6cjlv.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/Ron%20Francis%20Wiring%20Harness%20Early%20Bronco_ zpszxi6cjlv.jpg" border="0" alt=" photo Ron Francis Wiring Harness Early Bronco_zpszxi6cjlv.jpg"/></a>
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/Ron%20Francis%20Wiring%20Harness%20Fuse%20Block%20 Early%20Bronco_zpsynzd0z5s.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/Ron%20Francis%20Wiring%20Harness%20Fuse%20Block%20 Early%20Bronco_zpsynzd0z5s.jpg" border="0" alt=" photo Ron Francis Wiring Harness Fuse Block Early Bronco_zpsynzd0z5s.jpg"/></a>
 
  #16  
Old 04-04-2016, 01:53 PM
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So continuing on here's what I did for the engine mounts. I used a bunch of stuff I got from the scrap metal section so it was a little cheaper.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1942_zps39b830b3.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1942_zps39b830b3.jpg" border="0" alt=" photo IMG_1942_zps39b830b3.jpg"/></a>
I used my trusty "rusty" old metal bender to fit the sides of the block. This little tool works awesome and I got it cheap
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1943_zpsd161c7f9.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1943_zpsd161c7f9.jpg" border="0" alt=" photo IMG_1943_zpsd161c7f9.jpg"/></a>
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1944_zps9444dd4c.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1944_zps9444dd4c.jpg" border="0" alt=" photo IMG_1944_zps9444dd4c.jpg"/></a>
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1945_zps6b5f748a.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1945_zps6b5f748a.jpg" border="0" alt=" photo IMG_1945_zps6b5f748a.jpg"/></a>
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1950_zps475e3953.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1950_zps475e3953.jpg" border="0" alt=" photo IMG_1950_zps475e3953.jpg"/></a>
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1957_zps96880d9c.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1957_zps96880d9c.jpg" border="0" alt=" photo IMG_1957_zps96880d9c.jpg"/></a>
 
  #17  
Old 04-04-2016, 01:55 PM
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Heres the frame side. I used square tube so I wouldnt have to bend it and I think they came out pretty nice.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1958_zps0765b091.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1958_zps0765b091.jpg" border="0" alt=" photo IMG_1958_zps0765b091.jpg"/></a>
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1959_zps147d6d65.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1959_zps147d6d65.jpg" border="0" alt=" photo IMG_1959_zps147d6d65.jpg"/></a>
And here it is all welded in
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_3270_zpsd5f5a6e7.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_3270_zpsd5f5a6e7.jpg" border="0" alt=" photo IMG_3270_zpsd5f5a6e7.jpg"/></a>
 
  #18  
Old 04-25-2016, 03:55 PM
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So every day since I've been back from Moab I've been sick. I think my body was pissed for going back to this smog filled, concrete, over taxed, jungle called so cal. Oh wait lets not forget gun hating! I think I may be allergic to liberals. Is that possible?

Hopefully I can get to installing the Ron Francis harness soon. I think i have this cold handled so maybe this weekend I can add some current tech to this older stuff.

Continuing on here's what I did for the transmission mounts

I used square tube to set the angle for the mounts and to tie the two together. I figured since the front mounts were flat and square it would be a good idea to set the rear mounts at an angle to help center the engine and transmission.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1993_zpsfa99afff.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1993_zpsfa99afff.jpg" border="0" alt=" photo IMG_1993_zpsfa99afff.jpg"/></a>

I cut slots in the top of the tube and then bent it up until i got the angle i wanted.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1994_zps9bb1fb51.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1994_zps9bb1fb51.jpg" border="0" alt=" photo IMG_1994_zps9bb1fb51.jpg"/></a>

Here is the cross member with the notches welded up.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1995_zpsbc9e42ae.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1995_zpsbc9e42ae.jpg" border="0" alt=" photo IMG_1995_zpsbc9e42ae.jpg"/></a>

I made heavier duty brackets on each end where the mounts and transfer case would bolt to.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1996_zpsb4293072.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1996_zpsb4293072.jpg" border="0" alt=" photo IMG_1996_zpsb4293072.jpg"/></a>

Here it is welded and done
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1998_zpsfcf4bd04.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1998_zpsfcf4bd04.jpg" border="0" alt=" photo IMG_1998_zpsfcf4bd04.jpg"/></a>

Luckily I have a drill press I can use for big holes. I needed to drill a big enough hole to fit a socket through
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_1999_zps0f421a84.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_1999_zps0f421a84.jpg" border="0" alt=" photo IMG_1999_zps0f421a84.jpg"/></a>

Here's what I made for the frame side. They bolt to two existed cross member holes in the frame so I only needed to add two more.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2176_zps10785533.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2176_zps10785533.jpg" border="0" alt=" photo IMG_2176_zps10785533.jpg"/></a>

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2181_zps8e1f8a4a.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2181_zps8e1f8a4a.jpg" border="0" alt=" photo IMG_2181_zps8e1f8a4a.jpg"/></a>
 
  #19  
Old 05-06-2016, 12:31 PM
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Default Modifying the Oil Pans

With the engine and trans in place I mocked up my front driveshaft and realized that things were not gonna work the way they were so I made some modifications to the engine pan and the trans pan. Since I have a metal break I just put a 90 degree bend in both replacement pieces and that allowed me to trace the contour of the pan perfectly.

Here's the oil pan.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2227_zps86b201e8.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2227_zps86b201e8.jpg" border="0" alt=" photo IMG_2227_zps86b201e8.jpg"/></a>

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2228_zps3fb0cc43.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2228_zps3fb0cc43.jpg" border="0" alt=" photo IMG_2228_zps3fb0cc43.jpg"/></a>

My buddy Dave tig welded them up for me once I got them all trimmed and fitted. When it came to welding something that could leak there was no way I was gonna try it. Best to leave that to the real fabricators
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2249_zpsd4cc83e8.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2249_zpsd4cc83e8.jpg" border="0" alt=" photo IMG_2249_zpsd4cc83e8.jpg"/></a>

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2254_zps6c898ed8.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2254_zps6c898ed8.jpg" border="0" alt=" photo IMG_2254_zps6c898ed8.jpg"/></a>

I essentially did the same thing to the trans pan. Apparently the fumes from galvanized steel can make you sick if you weld on it so I had to clean it pretty far back from the weld point.
<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2220_zps9741a8c3.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2220_zps9741a8c3.jpg" border="0" alt=" photo IMG_2220_zps9741a8c3.jpg"/></a>

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2221_zps3dbd8f3d.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2221_zps3dbd8f3d.jpg" border="0" alt=" photo IMG_2221_zps3dbd8f3d.jpg"/></a>

As you can see Dave did an awesome job with the tranny pan too. and there were no leaks for either pan so we got it done on the first try

<a href="http://s8.photobucket.com/user/biggsyj1/media/4BT%20in%20a%201971%20Bronco/IMG_2250_zps4232ffaf.jpg.html" target="_blank"><img src="http://i8.photobucket.com/albums/a59/biggsyj1/4BT%20in%20a%201971%20Bronco/IMG_2250_zps4232ffaf.jpg" border="0" alt=" photo IMG_2250_zps4232ffaf.jpg"/></a>
 
  #20  
Old 05-07-2016, 09:40 AM
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Nice story line. Don't stop.
 

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