Bill's Early Bronco build

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As I was building fabbing everything for the frame , I left out a crucial and interesting tid bit of info regarding the atlas transfer case and the Bronco frame. The Atlas does not fit in it. When you see Broncos with an Atlas look under it and you'll see the Atlas clocked in a low slung position . It simply does not fit in the Frame. A company called Stack was making what was called a "B" box ( B for Bronco ) after market transfer case that was small enough to fit. I tried them and they were very unresponsive with no call back. It worried me so I stayed clear of them settling for the next best thing which is to notch and re-inforce the Bronco frame to clock the Atlas higher.

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So I have to put that thingy in that thingy ,, rust removal

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Tedious work. Tail gates for broncos are about 425 , very expensive . the piece here is made for rust removal and it cost 35 smackers . Just more work for a guy who had shoulder surgery a couple months ago .

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So I had this image in my head of what my step would look like , I wanted this thing to look a little better than the others I had done , so I took one over to Robert Youngs buddy , Bruno at the CNC shop . Told him what I wanted and he did it while I waited . $40 for both of them

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Back to the tail gate , welded it up and then put bondo on it twice then sanded it down , twice.

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Body filler

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I still was not happy with the tail gate there were simply too many little dings I had to mess with so I sold it on ebay for 300 and bought a new one from Wildhorses4x4. I was thinking the new tailgate would be ready to paint,,, wrong . There were annoying rivets sticking up that had to be taken down then body filler put in , then again ,, sanded, I only wanted the body filler over the rivets so I taped off the other area.

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The rivets on the new one

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The brakes on a one ton ford are huge twin piston calipers I simply don't need those huge brakes. I found a guy out of TN. who sold brackets to use the chevy 3/4 JB7 single piston calipers . Rotors must be changed to an 85 3/4 ton K20 4x4 P/U. They run about 40 bucks . I thought about scavenging them at the pick-ur-part then taking them to Richard G. to turn down. BUT ,,, I'm lazy.

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See the finger under the yard stick ? that's how much the door is bowed, I did some research on heat shrink and decided to give it a try