Copper Top

[blazinchuck]

So is the 1x1 on top of 2x6?

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[broncosbybart]

The 1x1 is to replace the outer rocker with something stronger, mostly to support getting in and out of the vehicle and for looks. The 2x6 will be attached to the chassis. There will be a 1/4" gap between the two.

A few years back I ran a set of fiberglass door inserts on a rig. I hated having to explain that they weren't for standing on. With this design the integrity of the rocker platform isn't reduced and there will be some distance between the door and the 2x6, which I like

[jac77]

Looks great!!

[broncosbybart]

Thank you!

Got some more work done. I think I remember where I left off here. I've been spending an hour or two after work working on it when I get a chance.

All the misc. unused holes in the firewall were filled. The lower sections of the kick panels were cut for tire clearance. I fabbed up some sheet metal and welded it in place to make a more stock appearing panel that still has plenty of clearance over the stock panel. This was done for each side.

The rear shock buckets were fabbed from sheet metal, welded and ground smooth. They aren't huge and don't take up too much space in the bed.

[broncosbybart]

While I was there, I filled all the holes in the bed and floor sections that will not be used and smoothed some of the other welds done by a previous owner. The interior and underside of the tub will be lined and what is remaining of the existing liner in the interior will be removed.

After that, I finished the outer rocker panel work and cut straight and smoothed what was left of the inner rockers. The original 2x6 rock skis that were on it will be fastened directly to the frame and will protect the body tub along these areas. I did the 1x1 square tube for looks and to strengthen the door sills. Hopefully the pics will make sense of it all.

[broncosbybart]

For my birthday, I was given some money by Sharon's grandfather. He is 94 years old and still going strong! He was a missionary in Africa and while he was there he had to build things, do mechanics, etc, just to survive. When he came back to the states he worked as a pastor and for fun liked to do woodworking. He enjoys seeing the things I do with metal and thought that I'd get a rivnut tool with his gift, as I've always kinda wanted one but never bought one.

So, this showed up in the mail. It was pretty reasonable and I ordered it with steel inserts instead of aluminum ones. I just like steel better. Neither of the doors had mirrors on them, so I measured and drilled some holes and in the pass. side and fixed the original filled holes in the driver's side. Broke the rivnut tool out and went to town. After that, the new Tom's Bronco black chrome mirros were fitted just for giggles.

Thank you grandpa S!

[broncosbybart]

Last thing for now is that I decided to 'shave' all the side marker lights. I cut some metal and welded it in place of the original marker openings. Hopefully it will be a good look. Only time will tell. And yes, the original belt line trim and spare tire carrier holes were filled and ground smooth as well.

And with that, sheet metal fab work is about done!!

[snipes243]

Looking good

[chuzie]

So will this one be attending Nov run next year?

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[jac77]

Looking great! Nice build all kinds of great mods