Project FSB: "Full Size Beater" - Ranger-Forums - The Ultimate Ford Ranger Resource


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  #1  
Old 08-23-2008
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Project FSB: "Full Size Beater"

Decided to get a thread going for the progress of the Bronco. It will be a chance for me to organize my progress and for you guys to have a look at the progress. I am trying to get alot of work done on it before winter with not many days to work on it during the week.

Truck:
-1989 FS Bronco
-5.0L V8 /AOD
-Long tube headers w/dual single side exit exhaust
-4" Lift w/35" Tires

Plans:
-Custom front and rear bumpers
-Winch
-Rock Sliders
-Rear cage, for use with hard top and a custom soft top.
-Custom soft top
-Hurc'd floor
-Body work,and repaint
-SAS w/D44 or D60
-38"-40" boggers or IROKs
-Fuel cell
-Cab cage
-Re-Run the exhaust higher
-Rear shackle flip kit

*I'll update the list as i find new things to do*



--> First set of pictures are of my first day of progress:

I replaced the broken Pass. side headlight/corner assembly as well as the broken grille. I replaced the fuel filter and dropped the gas tank, and removed all the brackets for it. I also cut off all the old exhaust hangers to clean up the underside. I need to order up my parts for the fuel cell thats going in to replace the tank as well.

Getn started

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Pic of the long tube headers meeting up to the true-dual glass packs. no cats.

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Gutted the interior,need to remove the sound tar stuff and then i'm going to Hurc. the floor.

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Removing the tank: I was under the impression it only had about 3 gal. in it. After i had it down, i filled two 5Gal. cans and then some. fun
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Nice pile of hidden goodies after the tank removal
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And the start of the junk pile
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End of the first day
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I'll use this picture to mock photochop my new bumper ideas

Last edited by INT3RC3PTOR; 08-24-2008 at 08:57 PM.
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Old 08-23-2008
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Looks good so far. Glad to see one of making some headway on a project. Haha...

I'll let you know tomorrow if I can get the bender operational. At the very least I should have the stand made up so we can roll it around. Only thing I probably won't get done is the Hyrdo as I don't think any places that sell lines will be open (at least back in WI).
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Old 08-23-2008
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Sweet. Looks awesome.

If you need any help let me know, im available pretty much every weekday and weekend evenings.
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Old 08-23-2008
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sweet, what tires are those?
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  #5  
Old 08-24-2008
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Ah, gotta love those 32 gallon fuel tanks.

Looks good, do it up nicely... for a beater. It's got a hell of a lot of potential and holyt crap is it clean!
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Old 08-24-2008
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Quote:
Originally Posted by SniperX103 View Post
Looks good so far. Glad to see one of making some headway on a project. Haha...

I'll let you know tomorrow if I can get the bender operational. At the very least I should have the stand made up so we can roll it around. Only thing I probably won't get done is the Hyrdo as I don't think any places that sell lines will be open (at least back in WI).
no problem,i still gota draw up my plans and such
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Originally Posted by malydeen View Post
Sweet. Looks awesome.

If you need any help let me know, im available pretty much every weekday and weekend evenings.
yeah for sure,there may be a few time when i need a hand getn my plate bumper in place during the build. since it may be a bit awkward and heavy.
Quote:
Originally Posted by 5speedin2.3 View Post
sweet, what tires are those?
They are buckshot mudders. generic mud tire
Quote:
Originally Posted by thesoundmaster View Post
Ah, gotta love those 32 gallon fuel tanks.

Looks good, do it up nicely... for a beater. It's got a hell of a lot of potential and holyt crap is it clean!
32gal? damn no wonder it seemed so huge hah. And yeah i plan to keep the build looking good, its my beater but i tend to make things look good at the same time. It is in ok shape, but there is alot of rust i have to deal with when the time comes. I have to replace the rear wells as they are completely rusted through. the guy who had it before the guy i bought it from, went mudn with the top off and the carpet and interior side walls were all rotten. so the guy i got it from ripped out the rear carpet and side walls. but there is a nice bronco at the j-yard ive been stealing parts from.
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  #7  
Old 08-24-2008
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I thought all FS Broncos had a 9", not the 8.8"? What year did that stop?

Fun toy, by the way. Keep us posted!
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Old 08-24-2008
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Awesome man!!! I want to get a full size bronco bad!!
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  #9  
Old 08-24-2008
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Looks like a fun project to tackle. Good luck and keep this thread updated as you go along.
I like reading these build up threads.
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  #10  
Old 08-24-2008
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Quote:
Originally Posted by AgPete139 View Post
I thought all FS Broncos had a 9", not the 8.8"? What year did that stop?

Fun toy, by the way. Keep us posted!
1987 or 88. I think there was only one year the 2nd generation FSB's came with an 8.8, then the 3rd gen's (like what's posted here) and 4th gens (92-96) all had the 31 spline 8.8's.
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  #11  
Old 08-24-2008
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Originally Posted by 98liftedranger View Post
Awesome man!!! I want to get a full size bronco bad!!
I regret ever selling mine. Once you own one, you will never be the same. I've even been looking for another one, simply because I miss mine so much.
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Old 08-24-2008
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yeah i got mine on impulse, when i went to see it i couldnt pass it up. Plus its fun to have a project truck again, and not have to worry aboput needing to drive it the next day.
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Old 08-24-2008
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looks good Andy -- ive got a FW HP D44 axle well parts lol

it just needs to be retubed, ive got the 2 piston calipers, NEW rotors, NEW ball joints, one flat top other just needs to be drilled..

i think it would be PERFECT (:
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  #14  
Old 08-24-2008
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looks
good
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  #15  
Old 08-24-2008
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Quote:
Originally Posted by HighRollerII View Post
looks good Andy -- ive got a FW HP D44 axle well parts lol

it just needs to be retubed, ive got the 2 piston calipers, NEW rotors, NEW ball joints, one flat top other just needs to be drilled..

i think it would be PERFECT (:
i'll think about it. but i may be going bigger
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Old 08-24-2008
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Originally Posted by INT3RC3PTOR View Post
i'll think about it. but i may be going bigger


ive got a FW HP D60 also lol with matching rear (:
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Old 08-24-2008
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hmm and what kinda bank you looking for?
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  #18  
Old 08-24-2008
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Stroke the beast out!!!

347 FTW!!!
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  #19  
Old 09-17-2008
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any thing new?
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  #20  
Old 09-17-2008
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that thing is cool looking
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  #21  
Old 09-17-2008
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Quote:
Originally Posted by AgPete139 View Post
I thought all FS Broncos had a 9", not the 8.8"? What year did that stop?

Fun toy, by the way. Keep us posted!

83 was the phase in year, by 87 all rear axles were 31 spline 8.8".

i suggest a sixlitre tune up (search fullsizebronco) and a Bassani y pipe instead of that abomination for an exhaust...better performance and mpg...because that 302 will be needing all it can get.
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Old 09-17-2008
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Quote:
Originally Posted by optikal illushun View Post
83 was the phase in year, by 87 all rear axles were 31 spline 8.8".

i suggest a sixlitre tune up (search fullsizebronco) and a Bassani y pipe instead of that abomination for an exhaust...better performance and mpg...because that 302 will be needing all it can get.

Yeah i plan on it. FSB.com is great for info. I'm hoping i can help the 302 with gears. but later on in its life it will be getting a bigger motor.


I've been able to do a little work on it when im not working. Mainly just getting some parts together, and getting a bunch of stuff done this weekend i'm hoping.

Picked up my f-150 gas tank swap stuff. 19gal tank, New sender/pump, f-150 sender plug, and the tank straps. I also scored a mint tailgate off a 95 FSB for $75(that included the tank straps and the spare carrier!). It just needs a new seal and some misc. hardware so i can put the glass i had in it. So finally i can have it all closed up. Next is getting the timing cover off and removing the broken bolt from the waterpump that was leaking from the last guy who had it(overhauled the heads and new cam) So i need to see if i can get it out and then RTV and rubber gasket it and it should be good to go.


Here are a few pics..

this is the bolt thanks broken off halfway in, and where its leaking
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All my fuel delivery parts to go in, and gain about a foot of clearance back in the rear.

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Spare gate i scored with the tailgate no charge. I plan on selling it though because its no good for a 37" tire.plus my truck doesnt have the threaded inserts for it.

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finally a tailgate, bit of rust on the bottom lip. but for an MN Bronco thats mint.

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Thats it for now. I'll get some more up this weekend, and hopefully soon i can get to the fun/cool stuff!
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  #23  
Old 09-20-2008
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Got a few more things done Today. Worked on gettin my window in the tailgate and putting the f-150 rear gas tank in.


I was missing some hardware and brackets for the WIndow install, so i had to fab a few things and find some nuts and bolts around the garage. But in the end i saved about $80 in brackets,hardware and seals.

Here is the Bracket i was missing on one side

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I made one out of some Aluminum angle

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Got it bolted in and it went up in the top with just a little help.needs some adjustments, but i can keep the weather out without a need for a tarp. And it rained just after i got it in

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For the F-150 tank to fit some cutting to the Frame is needed as well as removing the rear crossmember. WHich will be moved 5" back and flipped upside down and the truck tank straps will work like stock.

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Fits nice and snug up to the height of the frame. I will still be making a skid for it just incase a rock or stump hits it good.

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  #24  
Old 09-21-2008
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Really nice job so far, it's coming together quickly.
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  #25  
Old 09-21-2008
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Get late 91+ tailights for it if you have a chance. I can't stand 87-early 91 tails for some reason.



^1987 - early 91



late 91-96 and 97 "super duty"
~HJ

Last edited by HAZZARDJOHN; 09-21-2008 at 12:30 PM.
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