Rod's 84 BabyBajaF100

[AussieRod]

Thursday update:
Had a day off crook, vomiting most of the night, so after getting a few things done once I felt better around lunchtime, I went and bought some bolts, washers and Nyloks: :

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Then, started re-assmbly:

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[AussieRod]

Mas:

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Thats as far as I got tonight, had enough and needed a rest. Most of the bolts are firm tight, but tomorrow night I will break out the touque wrench and start torquing them to the proper tension. I have to swap some of the bolts at work, as I need 3 different lengths and could only get the middle one I wanted. I know I will need more as I go along, but 50 will get me by to get a lot bolted together. Atleast it is taking shape again, it's not a pile of painted pieces, it is now looking like a truck frame again! Might get to start the cab soon, after all the lines, cables and wiring are installed, along with the suspension and rear axle. Stay tuned.

[BajaF250]

I gotta tell you, I really like that "machine grey" color on the frame... very nice... it's going to look very nice under the truck when all the parts are populated! Sweet!

[Silverslk]

I agree !! I wasn't sure about that grey originally but its looking damn good Rod.

[tcm glx]

Its sexy and she knows it!!!! I like it Rod

[AussieRod]

Thanks, Guys Its a good feeling now she is going back together. I could have just done boring old reliable black, but then, this black sheep is already a standout, why not my truck as well?

[AussieRod]

Friday update:
Changed most of my bolts at work today, so I got more stuff fitted up. Gunna leave the torquing for tomorrow, my shoulder ain't playing the game tonight. But, progress was made until I ran out of washers and Nyloks again
Temporary beam pivot fitted with factory hardware and HT bolts:

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More pics of the assembly progress:

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[AussieRod]

Mas:
Even though I have welded the X member laps to the frame, and I removed the rivets there, I fitted new hi-tensile bolts to make sure there would be no flex in the welded area. I was surprised how much they pulled up before they went tight:

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Somehow, either I screwed up or Summit put the wrong part # on the website, but I ended up with the Energy Suspension 3" poly bush rear kit, instead of the 2.5" kit. I will research the correct width tonight, and just cut the tubes and bushes down to the correct width at work in the morning, and repair the spring hangers ready for paint and fitting. Then I will start painting/preping the radius arms and beams for thier fit-up. Once the TTB is all in, I will attack the rear springs and then tackle the diff re-assembly and get her on 4 wheels again. Then, or in the meantime, I will start fitting all the brake pipes, canister pipes and fuel lines, modified wiring harness, etc. Progress at last

[economig]

i'm almost afraid for you to touch that frame! ! !

ha ha again, lookin very good!

[AussieRod]

i'm almost afraid for you to touch that frame! ! !

ha ha again, lookin very good!

Thanks I use cotton painters gloves during assembly, so I dont mess with the new finish

[BajaBronco13]

Rod,

Your ride is coming out bitchin man! Nice work, keep going and I hope you feel better.

Chris

[Agui-E7TE]

Looking at your build is half making me consider doing a frame off restoration on my Bronco whenever I get around to rebuilding the engine. It's certainly a heck of a lot of work but you'll have one of the cleanest Ford's around when it's all said and done.

Did I mention I love the grey finish on the frame.

Keep up the great work Rod.

[AussieRod]

Saturday update:
Got more washers and Nyloks this morning, and after some domestic work, started finishing off the frame parts re-install. Then I broke out the torque wrench and buttoned up all the bolts, 45 lbs/ft on the 3/8" UNF hi-tensiles and 65 lbs/ft on the M12 HT's. Now I can pick up the right rear corner of the frame and up she goes, no flex. Then, I started laying out the TTB and hardware to start the TTB install. I wanted to make sure I have ALL the bolts, washers, etc BEFORE I start, so there is no holdups:

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[AussieRod]

Mas:
Springs and hardware. I have a cheap lift block kit I got off someone for free, but I wont fit it right now. Trying to keep it stock and simple to pass inspection:

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Chassis view:

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Tomorrow, after early shopping, I will clean and paint each piece, then fit it up. Some of it will be cleaned later and touched up before inspection time. I have decided NOT to pull apart thr rear leaves, as I will order either Deavers or go the Giant 64" kit for Stage 2. I will hit them with the rotary wire bruch to clean them up and paint them with the cheap gloss black, fit the rear bushings and install them. During the week, I will finish off the spring hangers, P&P them and fit them up and start cleaning and assembling the 9 inch. Stay tuned for more updates.

[Silverslk]

Thanks for the updates Rod. I've lagged on getting that stuff out to you but will try to find a big enough box.

[AussieRod]

No probs, Andy I just found out paypal didnt send the parts payment thru to you. I will see what happened and get it across.

[AussieRod]

Sunday update:
Got the TTB fitted in today, I was lucky my brother visited, and we manhandled it in. I made sure to time the intermediate shaft correctly on assembly so it wont wear/break/vibrate in 4WD. Gunna start on the rear spring hangers tomorrow at work and get them done so I can start on the back end.
Out with 2WD:

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In with 4WD TTB:

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I have some work to do on the floating floor in the house this week, so I will concentrate my work recoing the spring hangers first during the day (my breaks) and do some work in the house at night for a few days to help protect my ears from the squawking. I'll keep the updates coming as they happen.

[BajaF250]

Hey Rod,
I know it probably doesn't seem like it, but you are really kicking major butt on this project... well done Amigo! Nice job. This truck will turn out so nice!

[AussieRod]

Hey Rod,
I know it probably doesn't seem like it, but you are really kicking major butt on this project... well done Amigo! Nice job. This truck will turn out so nice!

Thanks, Tom, I'm really happy with the progress so far, all the pieces have fallen into place well. Once the frame is rolling, I will start on the cab and get that part under way. I still have some touch up to do on the TTB to pretty it up yet, but that will get done.

[AussieRod]

Wednesday update:
I 've been working on the spring hangers, bushings, sleeves etc at work during my breaks. It seems that my truck is odd, it has a 9/16 front spring bolt and 5/8 rear and shackles bolts, apparently contrary to what the Energy Suspension kit say I should have. ??? Wierd. The kit I should have ordered was 4.2114G (F150 2WD), not 4.2140G (Bronco, F150 4WD). Anyway, I had to shorten the sleeves and bushes for the rear spring eye and shackle, re-weld and drill the front hangers for the spring bolts to pass thru freely, they will be ready for P&P tomorrow night, along with the shackles. I hope to have the rear hangers cleaned up ready to do tomorrow night too. Have to stop off and get some more primer and paint and pick up the axle bearing kits for the 9" so I can get to cleaning and re-assembling it. I hope to have the rear suspension and steering installed on the weekend, then I will start on the wiring and brake/fuel/canister lines, etc.
Pics soon