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My new project: '88 Bronco
 
 PostPosted: Sun Mar 02, 2008 10:41 pm 

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I got a few hours of work done again. I put a layer of resin over the foam bead. I got everything sanded, scuffed up the low spots, cleaned all the dust off and started the body filler. My 4 year old gallon of bondo (only about 1/4 of a can, but a test mix showed it hardened still) ended up having chunkies in it. Anyhow, I picked them out as I went, but I am buying a new gallon tomorrow! I got the first layer on about half of the console, and knocked it down with the random orbit sander again. With any luck, I will have the whole thing with one or two layers on it by tomorrow night. I don't know yet how much it is going to take, but the filler work should go much faster than the glass did, the filler dries much quicker.

Here are the pics:

Image

Image

Later,
Jason

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Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Mon Mar 03, 2008 9:19 pm 

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It's getting closer. Got a couple more coats of mud on it today, keep sanding and filling. The passenger side is almost there, drivers side and back need a few hours yet. All of the sanding today was done by hand. Makes for a lot more work, but a lot better results. The top of the console is almost there as well. Edges around the openings will need more work yet.

Here are the pics:

Image

Image

Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Mon Mar 03, 2008 9:30 pm 

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that's sweet, you've got a pile of hours built up in that console alone......and with kids....... i can't get clear of the wife and kids long enough to change the valve cover gasket in my DD f-150 :argue:


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 PostPosted: Tue Mar 04, 2008 10:12 am 

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A little over 40 hours into it as of yesterday. I am only working on it a few hours a day. I typically would not have this many days in a row to work, but I took some vacation from work to help out with the new little one.

40-50 hours isn't too bad IMO, I thought it was going to take me longer, and honestly, a lot of the time I am counting was time spent waiting in the shop for the glass to set.

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Tue Mar 04, 2008 11:20 pm 

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I made a bit more progress on the console. One more coat of mud down and then sanded again. It is getting really close. The curves toward the front are 99% there. It still needs a little filler on the back and front sides. It got banished to the floor after that, as santa (aka. the UPS guy) brought me my new present. More in a bit, but first, here are the pictures of the console:

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And the present that UPS brought and caused the console work to grind to a halt...

Some of you probably read my "a different kind of gauge thread" it wasn't very eventful as no one had any input, but I received the Autometer mustang cluster today. It is indeed just the meter movements, and they are odd balls too. I spent a lot of time f-ing with it trying to get the autometer movements to work like the stock ones.

Unfortunately the way the motors are wound prevents using them the same way. The best I could get out of them was a 90° sweep. Not enough, not even close. So, I went with plan "b". I am putting the stock meter movements in the autometer cluster. It is pretty much the same thing they did, so basically what it amounts to is a fairly expensive (retail, not what I paid) set of white face gauges. They are EL back lit, and IMO look pretty cool, so it will be worth the work. The cluster itself is a much different shape than the stock one, but roughly the same size, so putting it in the dash should not be terrible.

So far, I have the voltage gauge, the oil pressure gauge (which I will mod to read true oil pressure) and the fuel gauge in place and verified working. I managed to break the coolant temp gauge, so if anyone has one that they want to sell, send me a PM. I have the guts from my aftermarket tach, and will be putting that in place of the autometer tach, and then there is the speedo to tackle. I should be able to use the micro from the stock one to drive the autometer movement, or I can use the stock movement there as well if need be, I am just not sure how I am going to calibrate it yet, but hopefully I will have the data sheets for the driver IC on the factory speedo board tonight and can formulate a game plan. At the very worst, I know I can set it so 80 mph is still full sweep on the gauge, even though it is only a bit under 180° sweep instead of the full 270° sweep to 120mph.

Anyhow, here are the pics of the cluster, the pic of the front is with the factory movements already in place.

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Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Thu Mar 06, 2008 1:39 pm 

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A bit more progress over the last night and today. I got all of the gauges hooked up and verified working, the only one I could not test was the speedo, and it will have to wait for when the bronco is on the road. I couldn't find any info on the speedo micro, lots of shops selling hardware to flash them, but at $7k I will find a different way. I found some promising datasheets for air core speedo driver ICs, if worse come to worse, I think I can build my own driver, but then I loose the ODO... We will see what happens. More on them later.

I got the 5th coat of mud on the console and sanded it again. It is really starting to take shape. I think it will need a bit more on the sides and back, a little around the shifter hole, and the openings still need a lot of work, but I have to knock the plexi out before I can go much further with those.

Here are the pics so far:

Image

Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Thu Mar 06, 2008 2:10 pm 
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strangler is hoser's shrink

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Tons of work.... looks great.

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Currently fearing a Rubiconish pile of parts......


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 PostPosted: Thu Mar 06, 2008 3:53 pm 

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Thanks! Coming from you, that really made my day :flipoff:

Okay, a few more very light coats of mud, and a lot more sanding, and here we are. The last few filler applications have been just for filling out the few low spots that remained, and hitting all of the edges to smooth out the exposed glass. The rest went toward filling all of the pin holes I could find. Of course, after sanding a bunch of pin holes came back, so before the next coat I will wipe it all down with a damp rag. First though it is going back in the truck to mud up to the dash good and tight. I have added a significant amount of size to it, so it is not going to fit perfect anymore. We expect this though, that is why it is going back in the truck :D

I would say we are at 99% right now (excluding the openings). All of the sanding/shaping up to this point has been with a farriers file, a cheese grater, and 60 grit paper on a home made 12" long sanding board. After the steps in the truck, I will be going progressively lighter grit until it is nice and smooth.

Here are the pics:

Image

Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Thu Mar 06, 2008 4:34 pm 

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The console is back in. The fit isn't as bad as I thought it could be. Less than a .125" gap. It is mudded in place now though, just waiting for the filler to set up so I can pull it back out and start working on the openings and finish sanding.

Image

Image

Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Thu Mar 06, 2008 4:42 pm 
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strangler is hoser's shrink

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Won't you have carpet under it?

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Currently fearing a Rubiconish pile of parts......


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 PostPosted: Fri Mar 07, 2008 12:04 pm 

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Yes, but I should have enough room. It doesn't sit tight to the floor. I may have to cut the carpet underneath the console, but I don't think so.

The progress so far this morning. Pulled the console back out of the truck. Knocked the plexi out. Started forming the openings. Sanded a bit more. Next step, wash it and hopefully start applying the last of the filler.

Image

Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Fri Mar 07, 2008 1:39 pm 

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that console is rediculous... in a good way.

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 PostPosted: Fri Mar 07, 2008 10:11 pm 

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Thanks! I think...

Well, I do believe that tomorrow it will be ready for paint. I spent hours sanding today, went all of the way to 320 grit, and then I bought a can of the duplicolor bedliner tonight (I have decided on the bedliner, and then matching gray dash and trim paint) and I find that the prep for the bedliner is 100 grit. So now I have to resand adn scuff the sucker up again. It is pretty for tonight though. I made some headway on the gauges as well. I have the mustang gauges mounted in the truck gauge can, and I test fit them in the dash. Fits great, no idea how the trim will come out there yet. I will take pictures of the gauge stuff after I finish up the console tomorrow.

For now, here are the pictures of the console.

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And I finally found a use for that old clumpy bondo, any guesses what it is for?

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Sat Mar 08, 2008 7:31 am 

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Hopefully the bondo brick will yield itself to being a good idiot light holder for the new gauges. I am going to mill pockets out of it and mount LEDs in it. My first attempt at indicator bulb holders was high density Styrofoam, and it worked well, but would not have held up for long...

**Edit** I meant to mention, after I took the pictures, I felt that bondo block and it was burning hot. Non contact IR thermometer said 180°, I was afraid it was going to melt the mold. Probably not a good idea to mix up that much bondo and let it cure in a solid block. I am pretty sure it hardened all of the way through, but I will be cutting it up today, and we will see.

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Sat Mar 08, 2008 1:07 pm 

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Hopefully the end is in sight. More sanding and touch up this morning and then I laid down the duplicolor bed liner. It really is a close match to the factory dash pattern. Hopefully it will give it a nice "feel" as well. The stuff goes down easy, but does not go very far. One 16.5 Oz can was just enough to give me three full light coats. I don't really want any more than that on there though, or the texture will start to really build. I am giving it 15 minutes or so, and then I will lay down the color.

Here are the pics:

Image

Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Sat Mar 08, 2008 3:46 pm 

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I got the color down, and I am not really happy with it. For one, the medium gray dash and trim paint, which seems to be the lightest gray they sell, is quite a lot darker than the factory dash. No big deal, I have bigger problems at the moment. It seems something went awry with the duplicolor bedliner. In the last pic you can see it. It must have ahd bubbles or something in the coating, and they popped when the color went down. There are all sorts of pin holes on the flat top of the console that were definitely not there before the bed coating. There are a few spots like this here and there on the sides, but that could have simply been missed spots from filling and sanding, but I don't think so. The sides are nowhere near as noticeable as the top though. So, what do I do? sand down the patches and reapply, or should I just try to fill the spots, either with a quart of bedliner, or possibly paintable caulk? Give me some advise? I have never dealt with this crap before.

Pics of the color, last one is the worst spot on the top.

Image

Image

Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Sat Mar 08, 2008 9:18 pm 

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I know it is likely I missed a few pin holes, but there are a ton on this edge of the console. I also know they weren't there when it was just in bed liner. Some of these are fairly big holes, about 1/8" in diameter, and there is just no way I missed that. I kind of think that the bed liner went on to heavy on the horizontal surface, again, yes, my fault, but I was following the directions. I doubt that it is any kind of chemical reaction, just the bubbles in the liner slowly making their way to the surface. The bed liner directions said at least 5 minutes between re-coats, I gave it 5 between each coat, and 15 before color. Much longer than 15 minutes and you don't get a chemical bond between coatings. I think I am going to fill the holes with caulk. Probably give it one more layer of bed liner and then go with a different color, as I really don't like how dark this gray is...

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Sun Mar 09, 2008 9:51 am 

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Yeah, you are right, I hadn't considered that. I was thinking last night though, how about I fill the spots with hot glue instead? A little bit of careful time with a hot glue gun and a single edge razor, and I should be able to fill them and smooth them nicely.

We will see, this is the last day I have to work on it. I am going back to work tomorrow...

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Sun Mar 09, 2008 10:54 am 
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strangler is hoser's shrink

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'bout time :poke:

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Currently fearing a Rubiconish pile of parts......


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 PostPosted: Sun Mar 09, 2008 2:59 pm 

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Well, I think the console is fixed. I filled the bad spots with hot glue and smoothed it out with a razor. Re-applied bed liner and I like it a lot. It has been about 3 hours now, and still no signs of pin holes. I am much happier now. I may leave it black, and re-do the dash to match. I really like how it looks.

The last picture is of what I am currently working on for the gauges. I have it all blown apart right now, I need to countersink and epoxy in the gauge stand offs, and this picture is of the factory speedo driver. I need to extend the connector for the ODO because it does not reach the spot under the tach. I finally got the ribbon connector de-soldered with out ruining the board, made a little PCB that will actually power the ODO LED back lights as well as hold one of the trip/reset buttons. 27 wires soldered in place to the new PCB, and I guess I should have measured, because I am still way to frigging short. So, next step is to de-solder all of the wires and make it longer again. That is all for this week though, it is back to work for me tomorrow. I should get a bit done next friday though.

Image

Image

Image

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Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Sun Mar 09, 2008 10:55 pm 
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strangler is hoser's shrink

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camaro13z28 wrote:
A little over 40 hours into it as of yesterday

I would have had the complete rig built 3 times by now and then parted out.... :thumb: :poke:

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Currently fearing a Rubiconish pile of parts......


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 PostPosted: Tue Mar 11, 2008 8:07 pm 

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I couldn't help myself, I needed the bench space, so I threw this in the bronco. I really, really like the black, and I think it contrasts well with the factory dash color. What do you think?

Image

Image

Image

Image

Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Tue Mar 11, 2008 9:14 pm 

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lookin good. maybe a lil' grey trim, or a grey stripe on it would really tie it together....... or maybe some more black on the dash..... really hard to say without seeing the seats in there too :lol: :woot:


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 PostPosted: Fri Apr 25, 2008 8:30 pm 

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No new work, but... My Cerwin Vega Strokers just showed up. Thank God for ebay! I found these old school gems for sale for $190 each, shipped. Brand new, in original packaging. I am sure there are newer, louder subs out there, but IMO old school don't get much better than this!

I will be running all Phoenix Gold amps, and probably all Phoenix Gold Zero Point interconnects if I still have enough in my boxes of goodies. Once I get it off the ground, I will update with the install.

The only thing I did not account for, is the subs are dual 2ohm coils. I did not realize that CV ever made the old school strokers in dual 2 ohm configuration. The date on the subs is 2000, and I guess I didn't realize they made this style stroker for that long either. No biggie in the end, it will allow more wiring flexibility.

So, here are the pics of the new additions to my collection...

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Later,
Jason

_________________
Jason Campbell

"Vehicles illegally parked here will be cheerfully disassembled and used for parts"

1985 CJ-7, 460,C6,BW1356,NP205, R/C Front D60, Standard Rear, 37" Irocks, 4 link front and rear, locked front and rear.


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 PostPosted: Mon May 05, 2008 8:38 pm 

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mmmm bass....... :devil:

:rocket:


Last edited by theonlybull on Thu May 08, 2008 5:14 am, edited 1 time in total.

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