Tag 1982 Ford Bronco

Published on August 24, 2025

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Part of the Truck Talk series.

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Show Transcript
I’m going to get you a little bit closer. Why? Because I’m a nice dad. No, you’re not. I’m not? That’s not very nice to say. Why am I not a nice dad? You’re a good dad. I am a good dad. No. No. Hug right here. All right, fine. Get out, you hooligan. Out. Out. Out. He’s telling you to get out. Bye, girls. Love you. Yep. Have a good day. Be good. Bye. Bye, Dad. Bye, kid. Here. Howdy, folks. Ed here. Welcome back to Bono’s Garage. Today, we’re trying something different. I’m going to call it Bullno’s Garage on the road. You guys have to let me know if you like this format or not. It’s something new. Basically, it’s just going to be me off the top of my head, driving on the way to work. During the summer, I’m sure you guys have noticed that I just don’t drop videos. I’ve said it before; I may sound like a broken record, but I just don’t have any time with the kids, family obligations, work, and everything else going on during the summer. There’s just no time to produce and film videos. I don’t have a lot of time, even in the evenings, but what I do have is a 20-minute commute to work. So, I think I’m going to try this little thing where you and I just sit in my truck on my way to work and talk. It’s not really a conversation because you’re not talking back to me, but it’s kind of like a podcast type thing, except it’s mostly just a YouTube version of that. Let me know if you like this because if you do, if you find it entertaining, then I’ll keep doing it. If you don’t, then I won’t. I have no problem not doing something if you guys aren’t interested in it. It’s just going to be talking about things like bullnose-related stuff, garage-related stuff, automotive-related stuff, and it’s just off the top of my head about what I find interesting or what I’ve worked on lately. I’m still working on stuff even though I’m not doing a lot of videos during the summer. I don’t have a lot of time, but at night after the kids go to bed, I can tinker in the garage a little bit or work on some things. I try not to work on the trucks too much without you guys there. I’ve done quite a bit of work on the Bronco and got it running. I have an interesting story about that too, which I’ll get to at some point. I’m not going to work on the F-150 without doing videos on it, but I also work on all the other garage-related stuff. For instance, I’m trying to teach myself how to weld. I’ve always found welding fascinating. How cool is it to stick two pieces of metal together with fire? That’s pretty neat. But I’ve never really gotten into it; I’ve never had the chance. It’s super useful. The number of times in my life that I’ve thought, “Man, I’d really like to get these two pieces of metal together” is way too high. So, I figured, you know what, I’ll learn how to weld. There’s a local place that has classes, but I don’t have time for that. YouTube is a thing, and welders are fairly affordable for the most part now. I thought, let’s go out and get myself a welder and give that a try to see if I can teach myself how to weld. I know I’m going to miss some things, and teaching myself is going to handicap me a little bit from the beginning because there are things that a pro or even a teacher would know that they could tell me right up front. I may teach myself bad habits and all that kind of stuff, and I understand that. But it’s something I want to teach myself and get into anyway. Ultimately, the goal is to hopefully get good enough to weld body panels. The Bronco has a little bit of rust right now. For the Northeast or near the coast, it’s not hardly any rust at all, but for down here, it’s actually quite a bit. There are a couple of places where there are holes in the body panels that are completely rusted through. I’d like to learn how to cut out a piece, weld in a replacement, grind it flat, and make it look nice so that you could paint it and not even know it was done. I don’t know that I’ll ever get that good, but that’s a goal. I do feel like I can at least get good enough to potentially weld a mount for a seat. I’ve got a back seat from a 2005 F250. It’s a rear seat with nice fold-down cup holders in the middle, and I want to put that in the F-150. Of course, those seats are not going to fit. They’ll fit dimensionally, but the mount points aren’t the same. So, I’m going to have to fabricate something. I want to get good enough to the point where I could at least fabricate that and feel confident in the welds I do so that I’m not going to go flying out of the vehicle at 70 mph with the seat attached to me because it’s no longer attached to the truck. Hopefully, I can get to that point. I’m not there yet, but welding is an art. Respect to you guys that do it because it looks easy. These guys on YouTube make welding look super easy. They just get out the gun, set the machine, strike an arc, and do some stuff, and then it makes a stack of dimes, right? But it’s nowhere near that easy to do. Look, it’s fairly easy to use a welder to get a couple of pieces of metal to stick together strong enough that if you bang it with a hammer, it’s not going to come apart. That’s not that hard. But making them look good and be truly structurally sound so that they can work in an application is a different story. I hope to get there. You can set yourself up for failure right from the beginning if you don’t get your spool speed correct, your wire feed speed, or your power levels. You need to use the right diameter of wire. You have to know how thick the metal is that you’re working on and what kind of metal it is. You have to make sure the metal’s clean. You need to have the right equipment. I went out and got myself a Captain MP205. This is not an advertisement for them. They have advertisements all over YouTube for this thing, but I’m not advertising for them. I thought about reaching out to them to see if they would give me one for free, but I’m just going to pay for my own stuff every now and then anyway. That way, I can talk to you guys about it without having to worry about some corporate sponsor. So far, so good. It seems to work pretty well. It’s a little expensive, but it does all the stuff right. It does MIG and TIG, pulse MIG, pulse TIG, and it even has a plasma cutter, which is cool. I’ve never plasma cut anything before in my entire life. That’s actually a lot harder than you’d think it would be, too. I tried plasma cutting, and I’m wiggling all over the place. The plasma cutter is like a lightsaber; it has no resistance whatsoever. It’s just a plasma arc slicing through metal like a hot knife through butter. It’s awesome, but it’s actually pretty hard to be straight. It makes a mess if you don’t have the settings right. I’ve found that using a cutoff wheel is better than the plasma cutter for me because it’s quicker to set up, and it cuts straighter, leaving cleaner lines. The plasma is undeniably cool, but I’m not great at it, so I’m wandering all over the place. Anyway, it’s got all that stuff, and I’m teaching myself with flux MIG for now because buying a bottle of gas, 75/25, is a whole thing. They’re expensive. You can get a bottle of gas for MIG on Amazon for 300 bucks, and it’s full. The problem is that I don’t even know if a place around here will fill it. What’s that about? It’s a legal bottle; it holds gas and has all the stamps and markings. It’s been tested and everything. It should be fine, but I guess some places won’t do it unless you buy their bottle because they want to make the money. To be fair, I haven’t checked with any place around here whether they will refill a bottle from Amazon. I have an 8 to 5 job, and all these places are open from 8 to 5, so I can’t just pop out of work and go down to the welding shop to ask about a bottle. I may have to take a day off one of these days to run some errands and make that one of my stops. Anyway, I’m teaching myself with flux, and it’s not bad. There’s a lot of spatter, but I feel like I’m doing pretty good. I’m building a welding table, which is the first thing you build when you’re learning to weld. I got some old angle iron from my father-in-law and found a couple of guys selling some old angle on Facebook Marketplace. The top is going to be an old industrial shelf, 4×2, that I just had laying around. I just tossed it together, and the angle is actually pretty nice. If you’re from the Southwest or some of the drier places, you know that a lot of less advantaged people will use what’s called a swamp cooler instead of an air conditioning unit. Swamp coolers suck, but they’re better than nothing, especially when it’s 100 degrees outside. Basically, you run some water over an element, and a big fan blows the humidity into your house, helping to keep the air a little cooler. They put these on top of roofs, and to get them up there, you need some kind of scaffold or mount. A lot of guys make those mounts out of angle; they just weld some angle together and plop it on top of a roof to hold the swamp cooler. Many of those are just hanging out in salvage yards around here. My father-in-law had a couple of those laying around, so I got those from him, cut the pieces off, cleaned them up, welded them together, and now I have the beginnings of a welding table. But like I said, I’m using a cutoff wheel. I bought a big cutoff wheel for my chop saw. I know you’re not supposed to use a chop saw. for cutting metal like that. It’s not really designed for that, but it works. It makes nice straight cuts, which is important when you’re building a table because you don’t want it to be wobbly, right? So, I got the table and I put some casters on it, and I’m working to put it together. But man, welding is an art. I feel like I’m not doing too bad. I’m definitely not stacking dimes, but I’m trying to learn how to see the puddle and how to manipulate it, and what pattern I like the best. There’s a lot of muscle memory involved. You have to know what angle to be at and your stick out, and how far away you are. I find myself wandering away as I’m going down the line, and that’s a problem. You have to keep the angle right. There’s a lot of stuff that you don’t think about, and you shouldn’t have to think about it if you’re a good welder. You just do it, and it comes naturally to you. I’m just waiting to get to that point. But like I said, I may never get to the point where I can do body work. I may end up trying TIG one of these days to see if that’ll be better for body work. But again, I want to get at least decent with the fundamentals of MIG before I do that stuff. Anyway, it’s fun though. I enjoy it. I look forward to doing it, but it’s a process. I got this MP 205, and it’s like an $800 machine, which I had to save up to get. But then you can’t just buy the machine; you’ve got to have all the stuff. You need a helmet because, god forbid, you don’t have an auto-darkening helmet. You may as well just throw in the towel. So, you have to get one of those. They’re not super expensive, but the stuff adds up. You need gloves, and a welding jacket or shirt to keep yourself from getting burned. You have to have the wire and the consumables, a cart, and a table. I’m building my own, but you still have to get the materials for that because not all the materials I have are from the junk pile. You need some stuff to stitch things together. It gets expensive, but I’m having a good time. I have a whole wish list full of things on Amazon to try to make my life better when it comes to welding. Who knows, it may be the flavor of the month for me. One of the issues I have in my life is that I get excited about something and I’m all in for a few weeks or a couple of months, or maybe even a year, depending on what it is, and then I just lose interest and move on to something else. So, we’ll see if welding is that thing for me. Luckily, the YouTube thing and the F-150 thing have stayed pretty well cemented. I’m keeping myself from playing video games at night because if I do, I’ll get sucked in and then I won’t make videos or do anything else in my spare time, which I don’t have much of. I’m teaching myself, and I’ll show you guys the welding table once it’s done. I’m pretty happy with it. I have some cool features planned, like a vice mount that rotates and some other neat stuff. I want to add my own touch and make it neat. Hopefully, one day I’ll be able to do the Bronco thing and weld some body panels together. Now, I look around and every piece of metal I see is an opportunity. I can build something out of that. I’m planning to build an engine stand, a run stand, with all the gauges, fuel tank, and radiator mount because those are expensive too. If I can build my own, that’s a win. But that’s one of those practical applications where you have to ensure you have good solid welds because, god forbid, the engine flops off while it’s running. It’s a learning experience, and I’m kind of a scatterbrain. I constantly set tools down and forget where I put them. I spend half of my time looking for tools, and I know I do that, but I still do it. I’m especially scatterbrained when it comes to something I’m not familiar with or new at. I was cutting some angle irons for this welding table and dropped a piece of angle iron right on top of a brand new set of Basset racing wheels. I think it’s Basset; I always mix it up with Barrett. I found a set of really nice painted red wagon wheels for the Bronco because I like that classic look. I was looking for a set, and some guy had them for sale on Facebook. I thought, “That’s perfect,” and he advertised them as five on five and a half. I brought them home and tried to put my hub on them, but the holes didn’t line up. I measured, and it’s five on four and a half. That’s on me for not checking it, right? So, I didn’t check it, and now I have these wheels I need to sell. In the midst of trying to sell these wheels, I found someone on Facebook selling Basset racing wheels, and I really like the look of those. I need a different lug nut for those since they’re racing wheels, but that’s okay; I’ll figure it out. I went out and got those, had them in my garage, and dropped a piece of angle iron. It hit the back of one of the wheels right where the bead seat is and left a divot. I believe the divot is big enough that it might cause a tire not to seat and hold air. However, they are steel wheels, and I’m learning how to weld, so I might be able to fix it by welding. I might try pulse welding for that because I think it will be better at controlling the heat and not blowing through. But I’ve never done pulse welding before, so I’ll need to test that on a piece of scrap angle first. It’s interesting that learning how to weld caused me to drop something onto a wheel that I can now fix by welding, now that I kind of know how to do it. We’ll see. By the way, these Basset racing wheels aren’t street legal. The ones I got aren’t even marked, so that’s another thing we’ll have to contend with. I will probably talk about that in another episode because I’m pulling into my parking lot as we speak. So, like I said, let me know if you like this format. It’s just me sitting in a truck talking, but it’s what I have time to do. It’s easy for me to edit these and get them out to you quickly. If you like this, I will keep doing it. I have all kinds of topics I could ramble about. I like to talk; I can hear myself talk. Anyway, thanks again so much for watching, guys. We’ll see you next time. She’s rough around the edges, but she’s doing fine. Getting things to shine at Moon Knows Garage. She’s considered divine. Thanks again for watching. We’ll see you next time.

Hey there, folks! Ed here from Bullnose Garage, and today I’ve got something a little different for you. Instead of the usual wrenching and walkthroughs, I’m taking you along for a ride—literally. Welcome to the new “on the road” format, where I share some shop talk during my daily commute. In this episode, I’m diving into the rust issues on my ’82 Ford Bronco, getting my hands dirty (and possibly burnt) with some welding, and the saga of my Basset racing wheels. Buckle up!

The Rusty Bronco Chronicles

Let’s kick things off with my 1982 Ford Bronco. It’s got a bit of the dreaded rust, which is a bit like finding out your dog has developed a taste for your favorite shoes. Not ideal, but not the end of the world either. In the Northeast, rust is as common as bad drivers, but this Bronco has a few holes that demand attention.

The goal? To learn how to repair these panels the right way. And by ‘right,’ I mean not using duct tape or JB Weld. I want to cut out the cancer, weld in some fresh metal, and make it look like it just rolled off the factory line—well, maybe not that good, but you get the idea.

Adventures in Welding

Speaking of welding, I’m teaching myself how to weld with the ArcCaptain MP205. It’s a nifty little machine that’s supposed to do everything from MIG to TIG to plasma cutting. In reality, welding is less about sticking metal together and more about developing a new form of cursing.

I’ve been playing around with flux core MIG welding, mostly because gas bottles are pricey and my garage budget is tighter than a lug nut on a cold morning. Spatter everywhere and a few burns later, I’m slowly getting the hang of it. The dream is to weld up some body panels on the Bronco, and maybe, just maybe, fabricate a seat mount for an F250 rear seat swap in the F-150.

Racing Wheels and Gravity’s Grudge

Now, onto the Basset racing wheels. I was all excited to pick up these beauties for the Bronco, only to play a cruel game of ‘angle iron meets wheel.’ Dropped a piece right onto one of them and left a nice divot where the bead seats. Because, you know, why not add more to the fix-it list?

Now, I’ve got a set of wheels that need selling and another set that need fixing. Maybe welding will save the day here, too.

Learning, One Mistake at a Time

Welding is an art, and I’m learning it the hard way. YouTube makes it look easy, but trust me, it’s not. Every weld is a lesson in patience, precision, and, occasionally, band-aid application. But I’m determined to get good enough to tackle those body panels and possibly prevent any future wheel-dropping incidents.

So, what do you think? Do you like this new format where I ramble while road-bound? If so, let me know in the comments. Your feedback will decide if I keep these “truck talks” coming. Thanks for tuning in, and as always, happy wrenching!

Catch you next time, and maybe by then, I’ll have a little less rust and a little more welding finesse.


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What does it take to swap a 1982 Ford Bronco from C6 to ZF5 4WD?


Bullnose Bill assists with the process of upgrading a 1982 Ford Bronco transmission.

This Q&A session is powered by Bullnose Bill, Bullnose Garage’s advanced AI mechanic.
Have your own question? Ask Bill!

Bill says:

I’m "Bullnose Bill," your friendly virtual mechanic specializing in classic Ford trucks, especially the iconic Bullnose models from 1980 to 1986. I’m here to help you with maintenance tips, repairs, modifications, and any questions you might have about these beloved vehicles. So, if you’ve got a question or need some advice, just let me know!


User avatar
User:

What is required to swap a 1982 Ford Bronco C6 to ZF5 4WD NP208?

Bill avatar
Bill:

Swapping a C6 transmission for a ZF5 in your 1982 Ford Bronco with a 351W is a great way to enhance your truck’s performance, especially if you’re looking for better gear ratios and improved drivability. Here’s a breakdown of what you’ll need to consider for this swap:

Parts and Equipment Required

  1. ZF5 Transmission:

    • Make sure to source a ZF5 that’s compatible with the 351W. Check for one that includes the transmission harness and any necessary adapters.
  2. NP208 Transfer Case:

    • You’ll need the NP208 transfer case, which is a great choice for 4WD. Be sure to get the correct adapter for the ZF5.
  3. Adapter Plate:

    • An adapter plate will be required to connect the ZF5 to the NP208. These can often be found from specialty suppliers or online.
  4. Transmission Mount:

    • The ZF5 will require a different transmission mount, so be sure to grab one that fits.
  5. Driveshafts:

    • You may need to modify your existing driveshafts or get new ones to accommodate the different lengths and locations of the ZF5 and NP208.
  6. Clutch Assembly:

    • Since you’re moving to a manual transmission, a new clutch kit, flywheel, and associated hardware will be necessary.
  7. Pedal Assembly:

    • You’ll need a clutch pedal assembly, as the C6 is an automatic and the ZF5 is a manual.
  8. Wiring and Linkage:

    • Make sure to check the wiring harness for compatibility. You might need to do some modifications for the new transmission. Also, ensure that the shifter linkage will work with the ZF5.
  9. Crossmember:

    • You may need to modify or replace your existing crossmember to accommodate the new setup.

Tools Needed

  • Basic hand tools (sockets, wrenches, screwdrivers)
  • Transmission jack
  • Torque wrench
  • Engine hoist (optional, but helpful)

Step-by-Step Overview

  1. Preparation:

    • Disconnect the battery and remove the C6 transmission and transfer case. Make sure to drain fluids and disconnect any wiring.
  2. Install Clutch Components:

    • Install the clutch assembly and flywheel before the ZF5 is mounted.
  3. Mount the ZF5:

    • Position the ZF5 onto the engine and secure it with the appropriate bolts.
  4. Connect the NP208:

    • Attach the NP208 transfer case using the adapter plate you’ve sourced.
  5. Modify Driveshafts:

    • Adjust and install the driveshafts to ensure proper alignment.
  6. Install Pedal Assembly:

    • Install the clutch pedal assembly and modify the wiring harness as needed.
  7. Final Checks:

    • Ensure all connections are secure, and fill all fluids before starting the vehicle.

Tips

  • Documentation: Keep the service manuals handy for both the Bronco and the ZF5; they’ll help guide you through the swap.
  • Community Resources: For additional insights and experiences, check out the Bullnose Ford subreddit or forums like Gary’s Garagemahal to see if anyone else has tackled a similar swap.
  • Take Your Time: This swap can be quite involved, so take your time and double-check everything.

This is a comprehensive project, but with some patience and the right resources, you’ll have a Bronco that’s ready for any adventure! If you have any specific questions or need more details on a part of the process, feel free to ask!



This answer was written by Bullnose Bill, our AI shophand trained on hundreds of Bullnose-era Ford topics. He knows his way around old Ford Trucks.

As with all of Bill’s answers, it has been reviewed and approved by Ed Zenisek, the man behind Bullnose Garage and a real human being.

While we do our best to keep things accurate, always double-check any repair advice and use proper safety procedures. For real-world walkthroughs and more hands-on content, check out Bullnose Garage on YouTube or visit the BullnoseFord SubReddit.


As an Amazon Associate, I earn from qualifying purchases. If you see an Amazon link on my site, purchasing the item from Amazon using that link helps out the Channel.

Published on April 4, 2025

Click to play the video inline  or  see it on YouTube

Part of the The Bullnose Bronco series.

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Show Transcript

anybody who works on engines knows that you need three basic things for an engine to run at least an internal combustion engine. You need air, you need spark, and you need fuel. Without any one of those three things, an engine is basically just a gigantic paper weight. Last time I was working on the Bronco on my channel, I uh took care of the spark problem because uh there was no battery in the truck and now there is and it works. And luckily for me, all the other spark stuff uh seems to be working okay. The distributor is fine, the spark plugs are fine, um at least fine enough to run the way that it is right now. I haven’t gone through and done a uh tuneup or anything, but it runs right. So uh air is also really easy ’cause I mean it just sort of sucks it from the atmosphere and as long there’s there’s uh no blockage anywhere, you’re pretty much good to go. But fuel, fuel is what I’m tackling today.

Howy folks, Ed here. Welcome back to Bullnose Garage and today I’m be looking at the fuel system of this Bronco, dropping the fuel tank and trying to figure out why it was disconnected. Hello! All right guys, so here’s what we’re looking at for this fuel system repair. Um for some reason, the fuel line right up here in the engine bay is uh was disconnected from the fuel line that runs back to the tank in the rear of the Bronco. And uh the guy that I bought it from just had it uh running with a bottle of gasoline, a water bottle full of gasoline that went right into the fuel pump. So I don’t know why that was disconnected. I don’t know if it’s um because the guy I bought it from just wanted to get it running really quick and so he just disconnected it and uh popped the bottle on there and he didn’t to deal with the entire fuel system or if it was disconnected for a different reason. Uh maybe that fuel line is blocked, there’s a problem with the filter, or there’s a problem in the gas tank. I really don’t know, so I got to go through the whole thing and I’m going to start with a gas tank.

Now, uh this was what was in the engine bay. This is just a a pre-arb oret fuel filter. I have no idea what the microns are, I have no idea what model it is. Um there’s not really any markings on it. I I’m I’m not going to use this. Um I’ve got uh a better idea. So depending on which model you have, whether or not it came from the factory with a fuel filter, a pre-pump fuel filter, um in the frame rail, my my 85 has one, this Bronco does not. There is a rubber hose connection down there between um the two metal hoses that a fuel filter could go on. I don’t know if it came from the factory like that, but that is what I’m going to do. Um I’m a fan of two-stage filtering, so I got a couple of 100 Micron metal filters on the way uh that I’m going to use to replace that. So for a pre-pump filter, I’m also going to do the one on my 85 while I’m working on it and uh then the post pump filter is going to be right uh in front of the carburetor and that’s just a little uh tiny Motorcraft filter. I’ll show you that when I get there. Um I’m going to replace both of them while I’m doing it uh on both vehicles, so uh there’s that. But first things first, I got to drop the tank.

Now dropping the tank in these isn’t real hard, but you do have to undo all the connections. There’s the fuel filler neck, there’s the uh um obviously the gas hose itself, the sending unit electrical, uh which is just uh power for the uh um the meter and ground, and then there’s the EVAP system which is just a line that runs from the gas tank for venting up to a charcoal canister uh in the front of the truck here. Now on both of these trucks, that charcoal canister is not hooked up to anything. It just runs from the gas tank up into the canister and then there’s nothing going to the uh the rest of the emissions system or the carburetor or anything like that. So um I think, I’m not sure yet, but I think I’m just going to cut out the canister in the Bronco and probably just put either an inline um evap valve on the tank itself or get a vented gas cap. I’m not sure which one I’m going to do yet, um but that’ll take care of that.

So uh yeah, once you got all those lines disconnected and everything’s kind of a free, then you put a jack underneath, uh start on doing the straps and the tank should just drop right down. So uh especially if it’s really old, a lot of those lines can be really hard to to get off. Um so you just want to be patient and uh jack the back of the vehicle up to give you some extra room to get up in there. Uh but yeah, we’re just going work on that and uh I’ll bring you guys along.

All right guys, so here’s our fuel tank for the 82 Bronco and uh outside it looks pretty good. The straps are a little rusty, but that’s not that big of a deal and uh I don’t see anything wrong with the tank. I think it’s empty, it feels empty, so uh that’s good. We’re going to see when I drop it if there’s any fluid in there, but I’ve already found a really kind of a big problem. Um whoever had this Bronco before me did some uh some questionable work in terms of uh the bumper hitch here and I kind of got like a rear-ended Pinto situation going on. So uh yeah, before I run this thing in any real capacity down the road, this is going to have to come off. I have said it before, say it again, inheriting someone else’s project is uh always an interesting endeavor.

So anyway, these are the straps. You can see that I’ve already got some PB Blaster um on the bolts there or the nuts to help me get that off there. And there up here we have the fuel line, so I’ve got to get that disconnected. Um somewhere there is a power cable I believe that goes to the sending unit that I’ve got to get taken care of and then also uh the uh fuel filler neck here, I got to get that um unclamped from there so I can drop this thing down.

All right guys, sorry I lost a little bit of footage, uh but it was just basically me unscrewing everything down here. So I am now ready to drop the tank. I got everything disconnected and I have the straps off. Well, the only thing I don’t have disconnected yet is the uh the sending unit electrical is not disconnected, but I can’t reach up there and get to that until I drop it a little bit. So all my hope is that I can drop this a little bit and then get up into there and I’ll plug it without this falling down and killing me. So let’s see what happens.

There we go. Ah, there we go. This is just about the exact right size to fit up into here. So oh yeah, all kinds of yeah spider eggs and all kinds of great stuff up there. See up here? Hey, there we go, it just pops right off the top. All right, now I should just be able to drop the whole thing down and should be good to go. Don’t kill yourself, Edwardo. This is pretty jank, right? That’s as low as that goes. Yeah, it feels like there’s a little bit of fuel in there. Oh, it’s the fuel filling neck. All right, all right, I’m just going to take that out. Yeah, there’s actually a bit more fuel in here than I thought there was, but it’s not too bad. There we go, all right, tank is down and the underneath of this actually looks really good.

All right, let’s get this puppy out of here and we can take a look at it. All right, so there it is. That’s the tank. Other than being pretty dirty, actually doesn’t look too bad on the outside. There’s not a lot of rust, I don’t see any corrosion, it does not feel weak at all. There’s a dent on the bottom, but that’s to be expected in a Bronco, I’m sure. Yep, get it open, take a look inside. Wow, that puppy’s not moving at all. You got your uh fuel sending unit lock ring here, which is a real pain of the keester. Um I’ve hit it with PB Blaster, I’ve probed to get it off a little bit. I’m going to try again here. Um really just got to keep at it. PB Blaster should soak in for a while using a brass punch so there’s no spark and so that the brass that the uh the punch doesn’t mar up my rings here. I don’t know if I’ll reuse this sending unit or not, but um we’re going to see what the condition is like and if it’s in good condition, there’s no reason to to replace it.

With something new, so yeah, let’s see if I can get this thing knocked loose. There we go. All right, looks a little rough but not horrible. There is some rust and gunk on there. Yeah, I will probably replace this just because of the rust on this arm and the way that that looks right there. Okay, there’s some gunk on the bottom, but man, the inside of that thing looks clean, and the gas actually doesn’t look that bad. It doesn’t smell that bad either for the age of the Bronco. Now, I don’t know how old this gas stank gets. It’s got dirt and debris on it, so it must have been there for a while. For the age of this, I am not disappointed in how clean this looks and that gas. I mean, you guys can, I don’t know if you see this or hear this. There you go. Yeah, see, now it looks like there’s a piece of Velcro or something in there. I don’t know what that is right there. There’s a little bit of sediment that you can see, but the gas itself looks pretty good, and the bottom of the tank looks actually really good. So here you go. Yeah, it actually looks pretty good in there. Happy with that.

All right, guys, so the next step is going to be to clean this tank out. I got to get the gas out of there, dispose of it properly, get it all cleaned up, and clean out the inside. I’ll go through with you on how I’m going to do that, what I’m going to use to clean out the inside to get whatever sediment there is in there out. While I’ve got it out, may as well go ahead and clean it up. I don’t know yet if I’m going to put a finish on this, like paint it or anything. I really don’t think I will. There’s no rust on it, and it’s in pretty good shape. I guess I could just spray a real quick coat of rust inhibitor or something on there just to, you know, while I got it out, clean it up and make it a little bit better. But, um, yeah, and then, obviously, like I said, I’m going to replace the sending unit because I don’t like the look of this. The float here, the arm that it’s attached to, there’s a lot of corrosion on that. So these sending units are not super expensive, so I’ll just replace that. I got to replace the fuel line. I got some new fuel line coming in. This one here cracked on me. I don’t know if I did that, if it was like that. It’s entirely possible that this was already there, and that’s why it was disconnected, that there was a fuel leak there. I don’t know. It’s hard telling. Like I said, I don’t know what all happened to this thing before I got it.

Yeah, so, and then this is the vent that would go up to the charcoal canister in the front of the vehicle. I had to cut this off with a knife because I couldn’t get it off any other way. I think I’m just going to put an inline vent here and take the charcoal canister out because it hasn’t been hooked up in my other truck either for basically forever, so it doesn’t really do anything. So it doesn’t seem to hurt the way that it runs. It’s one less thing to worry about, and so I’m just going to go ahead and put an inline vent in here or pop a vent in the top of here. I got to do some research on which way I want to go there. But other than that, yeah, so the next thing is cleaning it up.

Why you do that? W, that’s a lot of gas. Yeah, it is. It’s so huge. I feel like Go Go Juice. W, it’s called the pressure washer. All right, guys, we are in the garage, going to finish cleaning this up on the outside. There’s still a little bit of stickiness and some stuff here from where the strap pads were on either side here. Just a little bit of rust. I’m going to clean that up with a wire brush in my drill, and there’s some stuff on the inside of the tank. I’m not sure exactly what it is, like little bits and pieces. There’s like a cap of some kind, like a plastic cap or something in there. I don’t know how that got in there, if that was something that fell in there when I was working on stuff or if that’s something that’s been in there for a while. But I got my shop vac here. I’m just going to stick the shop vac inside there, clean it out real good, and then I’m going to hit it with the wire reel and get it kind of cleaned up. So we’ll do that next.

Sorry I got to shoot at night, guys. It’s a little dark out here, but this is the time that I got. You know, I work full-time and got a couple kids, so do what you can. All right, so I’m ready to do my acetone rinse, and I went ahead and put the old sending unit cap back on. I cut the rust and sealed it off. I’m going to replace that anyway, so I just got the cap in there so that it seals it. I found a lid to like an old masonry jar, so that actually just pops right on here. It’s not going to make an airtight seal, but it’s going to keep most of the vapors on the inside so it won’t evaporate too quickly. Then I’m just going to cover this with some metal tape. That way it won’t eat through the flash, and it should come off without leaving any residue. We’re going to see how this works. I haven’t tried this yet, but we’re going to give it a go.

So now all I got to do is pour my acetone in there and give it a swish. This should probably be good. Use a whole container. Obviously, guys, I’m doing this outside. You don’t want to mess with this stuff inside a not ventilated room like my garage. Probably should be wearing gloves, but I’m not. So the nice thing about this setup, and I didn’t plan it this way, it sort of worked out this way, is that acetone will, of course, evaporate over time, which can build just a little bit of pressure inside the tank. Not that it’s going to get dangerous or anything, but if you want to release some of that pressure, you can have just a little opening, and this actually works for that because this cap isn’t perfectly on here. It’s just kind of sitting on it. It snaps on really well, but it’s not sealed, so that will give me a little bit of an escape path for some of the fumes and stuff.

So, all right, I’m going to go ahead and swish this around and get the tank a good coat on the inside, and then I will leave it overnight. And then tomorrow, even thing, I’ll come back out and we’ll rinse it, and I’m going to use isopropyl alcohol for that, and I will tell you why I do that. Let that sit, and I will come out in just a little bit, probably another hour or so, and do that again, and I’ll do that until bedtime. And then tomorrow morning, I’ll come out and check it to see how much acetone evaporation I’ve got, and hope there’s still some in there. If there is, I’ll shake it again, and we’ll just go from there.

So we’ve had our acetone in there for just about 24 hours. I’ve come out three or four times over the course of the last day and swished things around. Got the acetone moving around in there. It’s actually not evaporated that much, so that’s good. You can get it sloshing out of there. So now I got to get the acetone out of there, and to expedite that process, I’m going to rinse with 91% isopropyl alcohol. This is about a quart of it. Isopropyl alcohol mixes really well with acetone, and it helps increase the evaporation time. It also binds with any water that might be left over in there from when I did the rinse out earlier, although there shouldn’t be anything in there. But yeah, so we’re going to use isopropyl alcohol to rinse out the acetone, and then we’ll use my air compressor to blow it out, make sure it’s plenty dry, and then we’ll talk about painting it.

So one thing I do want to mention here is that you’ve got a lot of options when you’re cleaning out one of these things. I used acetone for a couple of reasons. One, it’s pretty powerful stuff. It does a really good job of cleaning things. It dries really fast, evaporates, and it’s readily available. You just go to the hardware store and pick up a gallon like this. It’s a little expensive; they’re around 20 bucks for that gallon. But it’s so cheaper than going out and buying a brand new tank. You’ve got a lot of options.

You could use, now one thing that I use, acetone. I use acetone because there’s not a lot of rust on the inside of this tank. Acetone isn’t going to help you with a rust problem. If you have a rust problem, then what you might want to do is use like muriatic acid. And you be careful with muriatic acid, it’s pretty potent stuff. Um, make sure you’re not like breathing in while you’re doing the muriatic acid thing, uh, because it will get into your nose and just kind of screw you up, right? Uh, but I use it for the pool all the time that we have, so you know, I know kind of how it works and everything. But it, uh, I didn’t really need to use muriatic acid because I don’t have a lot of rust in there. I just have the gunk and the varnish from all the old gas, so acetone works pretty well for that. Uh, you could also use something like, um, Simple Green or LA’s Totally Awesome, some kind of degreaser. Um, there’s one called Super Clean in a big purple container that you could use if you want something that’s a little bit less, um, powerful than acetone. Um, but I like acetone because it does, it evaporates really quick. It’s really easy just to dump out, get on the concrete here, it just evaporates into the air, doesn’t hurt anything. One thing I am going to do before I, uh, I dump the acetone out and rinse everything is, uh, I got one of these, uh, she’s called a bottle brush, and I’m just going to open her up and get inside and just kind of swish things around and do a little bit of scrubbing with these nylon bristles. You don’t want to do a whole lot of that with acetone ’cause the acetone will eat into the bristles, but if you’re only doing it for, you know, 10 minutes or so, it’s not going to have any significant impact, really. So, um, I’m going to do that real quick just to get the last little bits out, uh, right before I dump it out and then rinse it with my alcohol. Now, I said there’s a lot of stuff you can use to clean these tanks out, and you saw me use my, uh, my pressure washer and water and some detergent to do this as my first stage. Um, and that’s totally okay to do. Uh, it’s much better for me here because we’re in a super dry environment, so, uh, the fact that I’m using water isn’t really going to institute any kind of flash rust or anything, I don’t think, down here. Um, and I didn’t, I can see inside clearly, there’s no, there’s no rust or anything down there. Um, but you do want to make sure that you get that water out of there, which is one of the reasons why I’m using isopropyl alcohol. I don’t know if you guys know this, but isopropyl alcohol actually binds with water, um, and helps it, uh, to evaporate much quicker. And you can use, um, like a, uh, reverse flipped, uh, shop vac or a, uh, air compressor to blow it out and just get it that much drier, that much quicker. Um, so I’m using isopropyl alcohol again because it’ll help, uh, dry faster than the acetone by itself, and if there just happens to be any water left over from what I rinsed it earlier, this will take care of that. All right, guys, so after looking at this tank and actually reading the directions on this undercoat stuff that I got from Rust-Oleum, uh, it says do not apply, it says do not apply directly over rust. I thought this stuff could do that. It says stops rust right there on the can, but it doesn’t say that you can apply over top of it. So what I’m going to use is actually some Eastwood Rust Encapsulator, uh, that I’ve got for another project, and hopefully I don’t use the entire can on this ’cause I need to use this for some other parts of the Bronco, actually, that are like the body that’s rusting out. I want to put this on top of the body to keep it from rusting too bad. Um, but since there is a light coat of rust on top of this, and, uh, I don’t want the rust to spread underneath the coat that I’m going to put, uh, the undercoating, I’m going to go ahead and spray this on there. And if I got to buy another can, I got to buy another can. So, uh, there you go. Well, there’s everything painted up with the, uh, Eastwood Rust Encapsulator. Um, now I’m not super impressed with this stuff. Um, it came out of the can really splotchy and, uh, kind of thick, and it, you, I don’t know if you can see all the drips and stuff that are on the floor, uh, that all dripped out of the can while I was painting. And I actually got some drips on the floor of my garage, which you cannot get up if you let it sit for more than like 2 minutes. Uh, you can’t peel it up anymore, so those are now white spots on my garage floor that are pretty much permanent. I mean, luckily they blend in with the other white splotchy stuff that are down there, but yeah, so I mean, we’ll see how well it dries and how well the black undercoating goes over top of it. I mean, I know how well you can see the, uh, the tank. This is about one can worth, and man, I mean, look at, you can see the splotchiness and the spots and the drips and everything. Now, like I said, I’m going to cover this with a black undercoating, so I’m not too worried about it. It’s rubberized, so it should be thick enough to cover up these little bumps and everything else. It’s not that it matters, this is the top of the tank, nobody’s ever going to see it, so it doesn’t really matter. This is just to cover up so that it doesn’t continue to rust. But I was planning on using this on the outside of my, uh, my Bronco. Can’t really see it over there, dark, but I was planning on using this on the outside of my Bronco ’cause it matches the white paint on my Bronco. But after spraying this, man, I don’t know. I don’t know that I would want to use something like this, um, on the outside of a vehicle like that. Now, I mean, it could be my technique, um, it could be that, you know, um, I just did it poorly or whatever, but I mean, I, you know, I, after my initial opening of the can and using it, I couldn’t even continue to shake it ’cause if I shook it, I’d get white splotches just went everywhere when I shook the can. So, I mean, this is all just dripping from the can as I’m spraying. So anyway, maybe I just got a defective can. Uh, I don’t know. I mean, if you guys have used this kind of stuff, let me know in the comments what you think, if maybe I’m doing it wrong or if I just got a bad can or what’s going on. But anyway, I got everything covered, um, so I should be able to, uh, cover it with the rubberized coating tomorrow. Hopefully that sticks a little bit better, and, uh, yeah, we’ll let it dry overnight and see how it goes. Okay, this stuff is nice. I like it. It goes on real nice, real easy. It looks real good. That’s impressive. All right. All right, guys, next step is to replace the pre-carb fuel filter, which is that guy right there. And for those be curious, there’s the information, just a little guy. And I believe that is, um, does it say what it is? I’m not sure if it says what micron it is. I think it’s 10, but I’m not 100% sure. Um, yeah, anyway, that’s your fine filter that’s right before your carb. So I have no idea how long since it’s been since this one’s been changed, but since I’m doing the whole fuel system, hey, might as well go ahead and do that. Pretty easy, just unscrew it and replace it. All right, guys, well, there she is all painted up. Had to move things outside ’cause, uh, it’s actually a pretty nice day today, so I can paint outside. And, uh, I was getting some overspray inside the garage on my garage floor, so moved it all out here. But I’m pretty happy with it. Looks really nice for a gas tank. So I’ve been working on the fuel system in this Bronco, and, uh, yeah, they did something here. I don’t know if that was, if it got melted or if they tried to, to somehow, uh, seal that or something. I’m guessing it’s melting. I’m not sure what’s going on there. Is, uh, like with any used vehicle that you don’t know the history of, there’s always going to be some other stuff. I’m doing an oil change and stuff on my other F-150 while I’m doing all this. I may as well do the fuel and oil and everything else, so we’re doing that. But yeah, they actually had, um, some plumber’s pipe tape on there on both sides of this filter. Now, guys, you don’t want to use plumber’s pipe tape here because, uh

Fuel can degrade that stuff and then it’s going to go into your carb and mess things up. So yeah, we got that taken care of. Now, of course, I haven’t run any fuel through this thing yet, so I don’t know if there’s any leaks. When I did this, there was a leak over here, but I got that taken care of. I just didn’t have it on tight enough, so that’s all there is to it. But yeah, and I got my new oil filter on there and some other stuff. So yeah, we’re working through things.

So I want to show you guys this too. This is the inline fuel filter that I’m using. This is the pre-pump filter. It’s Earl’s Vapor Guard, it’s 100 Micron, and that’s just to filter out any kind of big stuff before I get to the actual pre-carb filter. You don’t necessarily need one of these, but they’re fairly cheap, and I’m going to go ahead and use them anyway. I got one for both trucks. So the Bronco actually didn’t have a filter in that location, so I’m going to add this, and my ’85 F150 does have a filter in that location, so I’m going to replace it.

So here we are underneath the Bronco, and you can kind of see where we are. There’s the trans case, there’s the rear axle, and along the frame rail on the driver side is this little patch right here, and that is where the fuel filter is going to go. Hopefully, I’ve got enough room in here to put that filter. It’s going to be real close, but I think we can make it work.

All right, so here we are back under the truck. I got my filter assembly made up. I did this inside the garage; it’s way easier to do all that inside of there than out here. Got new pieces of hose, and the problem that I see is that this is going to be really tight. I don’t have a whole lot of room in here, so we’re going to see if I can get this all put together. I don’t know how I’m going to manage this. I think I have just enough room, but I don’t have enough room to like pop it on. I really don’t want to have to undo these brackets, but I may have to. I’m not sure what they’re going on with. Oh, it’s just like a plastic clip. Well, that’s bad news; that means I have to break them. It’s in brackets there too, and I don’t think I can move it back because it’s right against that cross beam back there. So how am I going to do this? Do I have enough room to do that? Oh, I can bend the rubber bits just enough. Hey, there we go.

All right, now unfortunately I don’t have my gas tank in yet, so it’ll be interesting to see. I have to monitor this real close for leaks once I get everything in. All right, so next task is pretty simple: hook this up to this completely new piece of hose. This one here actually looks pretty good, but I don’t know where it came from, so I’m just going to use the hose that I bought. But before I do that, I’m going to blow out this line and just make sure that it’s clear. I’m going to do that with just a little bit like compressed air. The can, this would be better if I could be two places at once because then I can feel the other end, make sure there’s air coming out, but I can’t be, so I just got to deal with what I got. Let’s see if this works. I’m going to put a little flat piece of, uh, bit like a white piece of, uh, it’s like concrete sludge stuff, kind of, but it’s real light. It’s like the stuff that sits on top, and I’m going to see if I can blow that off there from the end. Survey says, well, it’s gone. I guess I’ll have to review the footage and see if they actually blew off of it. All right, well, I guess we’ll see if that leaks when I start her up. Got to get the fuel tank in first though.

Well, for some reason I lost the audio to this part of the video, but that’s okay. Really, all I’m doing here is just going through, showing you some of the parts that I’m replacing and kind of giving you an overview. So you can see in the background there that the tank is done, it’s painted. I’ve got the straps also painted all the way around. You can see that right now I’m putting in the new gasket for the EVAP valve that goes on top there. The one that came with it, that I pulled out of the truck, was pretty well rotted away, so I just replaced that. Again, that’s not very expensive, just like the sending unit. And also, you can see on the tank there that I’ve got some neoprene strips. It’s just rubber neoprene that goes on the top there, like I think it’s like an inch and a half wide, just lays in there. I took some spray adhesive and put it down there so it doesn’t move around. I mean, once I get it mounted, it’s not going to move, but that’s just to keep it where I want it while I’m mounting it onto the actual Bronco when I get to that point. And you can see over there on the right-hand side where I’ve got the straps already with the same exact treatment. I put a piece of neoprene rubber on there with some spray adhesive just to kind of keep everything together.

Here I am putting the new gasket for the sending unit together and getting ready to put the sending unit in. The new sending unit wasn’t very expensive, so that’s worth replacing, especially considering how coated that old one was. So yeah, just kind of putting the finishing touches on the tank and getting ready to mount it up. Woo, just get out of the way. So now I got to get the fuel filler hooked up. Having kind of dread in this, to be honest. Probably got to get the hose clamps on before I do all this crap, huh? All right, well, here we are about to hit the moment of truth. Everything’s hooked back up, and we just got to get the gas.

All right, guys, here it is, proverbial moment of truth. A, that was cheap. That, and there’s clearly some other stuff going on here too, guys. It smokes pretty bad and doesn’t want to stay running very well.

All right, guys, real quick fuel line and brake line 101 here on Bullnose Garage. This is a flare wrench, or called a line wrench. You want to make sure that you use these on your fuel lines and your brake lines, another kind of flare nut lines, because if you don’t, what you get is this. Yeah, that is what’s left of the nut that goes from the fuel line or on the fuel line that goes into the carburetor on the Bronco. And yeah, that’s pretty well mangled because somebody at some point in the past did not use a flare nut wrench or a line wrench on that nut. As a consequence, trying to get that put back on, I kinked the hose badly enough that it actually has a couple of holes in it. So when I did my startup test, it was actually spraying fuel into the engine. Now, I don’t know if the little bit of fuel spray that this was doing is enough to cause the engine to not run at idle like mine didn’t very well. So, you know, we’re going to find that out because I’m going to put a new fuel line on it. I’m actually just going to use a rubber fuel line, so I’ve got a couple of these flare nut fittings that’ll go in there, and then you just clamp a hose, a fuel line onto there. And I’ve got one for the carburetor side and one for the fuel pump side, so I’m just going to use a regular rubber hose instead of the metal piece there. Now, if I was getting super fancy, I could use like, you know, braided steel hoses and stuff, but I’m not going to do that right now. So yeah, we’re going to get this on and see if that fixes the issue.

So I don’t know if you guys are anything like me or not, but if I got a problem that I think I might have the solution to or know how to solve, even if it’s the middle of the night, I’m going to be working on it because I can’t just let things go and sleep on them. So that’s what I’m doing right here. You can kind of see there’s my new fuel hose going down to the fuel pump, down to the fuel pump and then up to the carb. And we are going to see right now in the middle of the night if it actually makes a difference. We’ll mount you. It’ll be a little bit wobbly, and we’re going to mount you right to the truck here. Here we go. Okay, so there’s a couple things that I’m looking for here to make sure of. One is that this doesn’t leak right here.

This doesn’t leak right here, and then it actually will run at idle without me having to goose it. So, uh, we’re going to see if any of that stuff happens. Okay, it is running. I’m not in the truck. It’s a little rough, but I don’t see any leaks. I mean, I feel like I probably also have some vacuum issues going on, but this is definitely better than it was. Oh, start to get some smoke now, so we’ll have to troubleshoot that. Oh, almost lost it. Yep, so we got some work to do, guys.

All right, guys, here we are. It’s a couple weeks later. I haven’t had much of a chance to work on the Bronco, uh, but I’m going to wrap this episode up and just let you know that all the fuel stuff is in. The tank is back up. I got fuel in there. Um, unfortunately, the Bronco won’t stay running. Uh, it’ll run for just a little bit, uh, but then it dies. If I give it some gas, it’ll run choppy, um, until I take the gas off. And then I, I don’t have time to get around to the front of the truck to see what’s going on before it dies. So I’m going to mess with the carburetor a little bit, see if I can get the idle tuned up, uh, so I can at least have it run long enough for me to come over here and see what’s going on.

I got to check fuel delivery because I just worked on that system, so it could very well be something going on there. Um, I got, uh, the vacuum system. The vacuum in this truck has been, uh, just mangled. So I, I don’t know, um, what else is going on with the vacuum system in there. There may be a vacuum leak. Um, who knows? There’s a lot of stuff going on. So, uh, but that is another episode. So, uh, yeah, thanks for watching, guys. As always, if you have any questions, comments, concerns, gripes, or ramblings, stick them below, and we will see you next time’s. Edes but’s away getting things to shine. Oh, no, garage considered divine. Thanks again for watching. We will see you next time. Thanks again for watching. We will see you next time.

Hey folks, Ed here from Bullnose Garage. Today we’re diving into the deep end of frustration with my 1982 Ford Bronco. I’m tackling the fuel system, and let me tell you, it’s been a ride. Spoiler alert: despite all the wrenching, the Bronco is still giving me the cold shoulder.

Dropping the Tank: A Glimpse into the Unknown

Dropping the fuel tank on a Bronco isn’t exactly brain surgery, but it does require a bit of finesse. You’ve got to disconnect the fuel filler neck, fuel hoses, and the EVAP system, among other things. In theory, it’s straightforward—just put a jack underneath, undo a few straps, and voilà, the tank should drop. But in practice, it’s more like wrestling a greased pig.

I found myself staring at a tank that looked decent enough, but the mystery of why the previous owner had it disconnected remained unsolved. Turns out, the guy was running the Bronco off a water bottle full of gas. Classy, right?

Inside the Tank: Surprises and Gunk

Once I got the tank down, the outside of the tank was surprisingly clean, but the inside told a different story. The sending unit looked like it had been through a war. Rust on the arm and some questionable gunk at the bottom made it clear a replacement was necessary.

Despite the grime, the gas inside wasn’t as bad as I expected. A bit of sediment, sure, but nothing catastrophic. Still, I decided to clean it out thoroughly. Acetone rinse, followed by isopropyl alcohol to dry it out—because why not make a science experiment out of it?

Reassembly: New Parts, New Problems

With everything cleaned and new parts in hand, it was time to reassemble. I replaced the sending unit, added some new fuel lines, and even threw in an inline fuel filter for good measure. Of course, the rear bumper situation—a rear-ended Pinto waiting to happen—needed addressing too.

The new setup was looking promising, but as with any project car, it’s never that simple. I fired her up, and she ran… for about a minute. Then, splutter, die. Classic.

The Never-Ending Saga

So what’s next? Well, my Bronco still refuses to stay running. It could be a vacuum leak or something up with the carburetor—I haven’t ruled anything out yet. I’m gearing up for round two, where I’ll dive deeper into the mystery.

If you’ve got any theories or tips, I’m all ears. Drop them in the comments because heaven knows I could use the help!

Check out the video above to see the chaos unfold, and stay tuned for part two. It’s only going to get more interesting.

As always, thanks for watching and wrenching along with me. Let me know what you think, and I’ll catch you in the next episode!


Bullnose Garage at YouTube

If you want more specific information on Bullnose Ford Trucks, check out my YouTube Channel!

For more information on Bullnose Fords, you can check out the BullnoseFord SubReddit or Gary’s Garagemahal. Both are excellent resources.

As an Amazon Associate, I earn from qualifying purchases. If you see an Amazon link on my site, purchasing the item from Amazon using that link helps out the Channel.

Bullnose Bronco

Published on January 30, 2025

Click to play the video inline  or  see it on YouTube

Part of the The Bullnose Bronco series.

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Show Transcript

You know guys, sometimes doing YouTube is hard, and it takes a lot of time to make videos and a lot of time to sit down and do the research and write the scripts and do all this stuff. So I thought this week I’d try to catch up a little bit, just do a real quick simple video about my plans for the Bullnose. You know, I haven’t done one of those in a while, and that way you guys can kind of see what the plans for the Bullnose are going to be. So, uh, oh, I, uh, yeah, you already know the plans for this Bullnose. I mean, the plan for this Bullnose. Hello, hi folks, Ed here. Welcome back to Bullnose Garage, and meet Bullnose number two. She’s a 1982 Ford Bronco. Just picked her up this weekend from my actual friend that I’ve got in another town over. He saw my channel, went, ‘Hey, I got a Bullnose rotting out in my yard. You want to come pick her up and add her to your list of projects?’ I thought, ‘Ah, you know what? Why not? Because one Bullnose is never enough, right? Mongo’s Garage, mm, I’m coming for you. I got two now!’ Actually, no, I will never have as many Bullnoses as those dudes have. That is crazy. Anyway, I just thought I would introduce you and let you take a look and talk a little bit about what my plans are.

So this old girl is much rougher than my ’85, but one thing I love about her is that she has a manual transmission. Of course, being a Bronco, she’s a 4×4. She’s pretty rough, but you know, that’s okay because I’m going to cut my teeth on my ’85 and learn my way in and out of these things really, really well, and then we will start restoring this girl right here. Now, as you can see, she does have a little bit of rust coming in down through here and some back over here. My guess is, I’m not sure if you can see that from the camera. I guess you can. And so my guess is that the guy who the previous owner had was doing some mudding and some off-roading and stuff, and those tend to be the places where the mud and the grime and the stuff gets caught up in the fender wells and up inside of here. And so that’s where a lot of dirt and debris and G got caught up in there. As a matter of fact, I can see some, um, already in there. See if I can feel the dust coming out of there. Dust and dirt with grunge and stuff in there. You can actually see where there’s some rocks and dirt caught up inside of there. So my guess is that that stuff got wet and just stayed wet for a while, packed up in there, and that’s where that rust happens.

You got the same thing over by the tailgate. You can see pretty clearly down here on the bottom there. So this tailgate is pretty much roached. I could probably fix this, I guess, but I don’t think I’m going to. They make repop tailgates for these, so I’ll probably just go ahead and do that. The rear window, unfortunately, doesn’t go up and down. I think that’s probably because the motor is busted. So the rear window has been down for a long time, and so that’s allowed the elements to get in here. So the inside of this, especially in the back, is pretty well roached out. But you know, it wouldn’t be a project if it was easy. So my current plan is to take the tailgate off, replace it with a new one. Probably I’ll cut some panels out of this and use them to fill in some of the body areas and the other parts of the truck that are a little bit rusted out. Teach myself how to weld body panels and do some fill and that kind of stuff, just kind of make it look nice. This one, the plan is not to be a show truck like my other truck is. This one is actually going to be something a little bit different.

So my plan for this truck is to be a desert crawler. We’re out here in the desert Southwest. There’s a lot of trails and mountains and stuff here, so I figure I could, uh, you know, it’s kind of pretty much already set for it, right? That’s what a Bronco is. So, uh, I’m not going to go like full pre-run or anything, but just, you know, give it like maybe a 4-inch lift with a 1-inch body lift, and I’ll put some bigger tires on it. You know, it’s already got the 49 in the rear, and it’s got a J44 TTB in the front. And I think, uh, you know, if I just beef up the components for both of those, that should give me what I need to be able to go out and do some serious desert crawling around here. You know, just kind of clean it up and clean up the rust and make sure that it runs right. Now, it’s not roadworthy, unfortunately. Now, it does run, and it actually runs like a top. It’s got an inline six in it, which is awesome, and I think the inline six in this thing runs almost as good as the inline six in my ’85. Now, of course, you guys that are paying attention to my channel all the time know that I’m pulling the inline six out of the ’85 and putting a 351 Windsor in and stroking it to 408. That is not what’s happening to this thing. You guys don’t have to worry. This truck is keeping the inline six. I probably will pull the inline six out of this and do some refreshing on it. I may decide to do some mods to it. You know, there’s some talk in my channel comments about, you know, did you see this where they turboed inline sixes and all this stuff? You know, I might look into some of that stuff. I don’t know that I have the chops for a project like that yet, but you know, by the time I get done building my Windsor and stuff, maybe I’ll feel more comfortable around that stuff, so I might give it a try. Anyway, but regardless, the inline six in this thing is a puller. It’s a workhorse. It got me up on the trailer no problem. There’s some fuel issues, so you have to actually, uh, here, you know what? I’ll show you. There we go. Ah, all right, so there we go. There’s the old inline six in there, and right now the only way I can get it to run is to throw some fuel in a water bottle like this and spray some fuel down in the carb, and then she’ll run. And she runs really, really good. The inline six in this purrs like a kitten, so I’m really happy about that. But, um, I’m not sure what’s going on with the fuel line. I’m not sure why it can’t pull fuel from the fuel tank. I got to look into that. The brakes are basically shot. When we dropped it back off the trailer, I had to actually put it in gear and pop the clutch to make sure that it didn’t roll back into my wall over here. So, uh, yeah, the brakes are pretty much shot. I got to do a complete brake job. I’ve already got a video series on my complete brake job on the other truck, so I won’t bore you with doing that whole thing again. But at least I know what I’m doing there, so I’ll do that. It needs new parking brake. Yeah, obviously. I mean, there’s no, uh, coating in it. There’s, uh, I don’t have any idea what the condition of the oil is. Um, you know, I got to look at all that stuff. But the engine itself runs really well. And you know, my thought was that even a worst-case scenario, the engine in this turned out to not run very well, I can always pull the 300 six out of my other truck and pop it in here and use that. But I don’t think I’m going to have to. I think I can just use the 300 that’s in here, and we’ll see. You know, I’ll get them both out at some point and see which one I want to use for my rebuild.

But yeah, so if you were paying attention to the engine when I had it closer up here, one thing you’ll notice that this truck does not have is air conditioning. And if you’ve watched a couple of my videos before, you know that I specifically bought my other truck because it has air conditioning and because it’s so damn hot down here in the Southwest when it gets to be in the summer. So, uh, that’s kind of okay for this build. Again, this is not going to be an around-town cruiser, really. It’s going to be mostly going out in the desert and having fun. So most of the time, I think this will have windows down, top off, that kind of stuff. But, uh, I still think I want to put AC in it, so I may make a video series about putting AC in a non-AC Bullnose. Um, because that’s, you know, I think that’s worth the content. And I actually do have a dash already from an AC Bullnose truck that I might be able to use as parts and pieces for this. I don’t know how hard that’ll be. I haven’t actually done the research to see how hard it’ll be to put an AC in a non-AC truck, but there are kits that you can use that’ll do that even if you don’t use the factory AC. So, um, yeah, we’ll see how that goes.

All right guys, here we are underneath the Bronco, and you can get a good look at what’s going on down here. There’s the Dana 44 front TTB, and, uh, let’s see, this, believe it or not, is an NP435 transmission. This is the same manual transmission that I got in the ’85. Um, with these trucks for a manual, it’s either going to be a T18 or an NP435, and you can tell this was an NP435 because it’s got the PTO cover on the passenger side right there. You can also see the drain plug is indicative of an NP435 too. So, uh, yeah, same transmission, and that transmission is going to stay in here because NP435 is basically bulletproof, and it’s perfect for a desert runner, desert crawler like I want to build here. So, uh, yeah, as long as it shifts well, which I think it seems to so far, but I haven’t had it out on the road to test it. But yeah, so we’re definitely going to keep that. And as you can see, there’s not really a lot of rust. There’s some surface rust on the frame, nothing real bad. There is some rust there under the seat pan. I think that happens quite a bit in these trucks, so I’ll have to cut that out, put some rust inhibitor or converter on there, and eventually cut that out and probably weld a little pan or something in there to make sure that doesn’t get any worse, make sure it can support my amper frame while I’m in the truck. And then, uh, yeah, so scoot back here. All right, scooting back just a little bit, you can see the transfer case here. I believe it’s an NP205, although I’m not 100% sure. I got to check this tag here and double check, but, uh, I think that’s going to be what it is. Believe it or not, guys, I was wrong. It’s actually a Borg Warner 1345, not a New Process 205 transfer case. Both of those transfer cases were used in this era of Bullnose Broncos, so I wasn’t sure which one it was, and I took a stab, and I was wrong. They’re both really good transfer cases. They’re both pretty similar. The Borg Warner’s got a chain drive, and the NP205’s got a gear drive. I’ll do another video about the differences in the different transfer case options that there are, but I think I’m probably going to go ahead and stick with what I’ve got. I’ll do a service on it and make sure that it runs okay. But, uh, yeah, so it’s a Borg Warner 1345. And then, uh, yeah, you can see underneath here to the back, got the famous Ford 9 inch, which I’m super excited about. It’s not an end case, though I wouldn’t expect it to be an ’82 Bronco. So, uh, but it should still do perfectly for what I want. Beef it up a little bit, put some high spline axles in there and, you know, a locker and some stuff, and we’ll be good to go there. And then, yeah, the driver’s side of the body here doesn’t look too bad. Um, so I think I’m in good shape. There’s some surface rust on the cross member and the frame and just in general, but there’s no rot through. It’s just surface stuff. So, man, got rust falling on me. Uh, but hey, you know, that’s part of the job. So, yeah, um, I’m super happy with it. I’m looking forward to digging into this thing and see what we can make out of it.

All right guys, well then, these are the twin sisters of Bullnose Garage. They’re not identical, just like my other twin girls aren’t identical, but they’re both the same vintage, and one’s an ’85 F150 and one’s an ’82 Bronco. Um, yeah, I’m super, super thrilled of them both. Can’t wait to get them both on the road and going. This one here will obviously get done first. Uh, this is one that I put the new engine in, the 408 that’s going to go in here. Uh, this one has got a lot of work yet to do. I got to do some body work and, uh, obviously work on the engine fueling system, brakes, all that stuff. The fiberglass cab’s got some issues. Some of the fiberglass is kind of getting worn down. I got to, uh, probably coat that and put a coat of paint on it and stuff. But you know what? I’m going to bring you guys along for all that stuff. Uh, you know, this whole channel, everything’s about me cutting my teeth and getting some experience on some of the stuff that I don’t really know that much about. So, uh, yeah, looking forward to getting both these girls fixed up and ready to go. And if you want to be along for the ride, make sure you like and subscribe. I really appreciate that. And like I said, I got that 408 that I’m getting ready to build that’s coming up on the channel. So if you want to see what I’m doing there, make sure you subscribe and, uh, you know, ring the bell and keep in touch with all that stuff. If you have any questions, comments, concerns, C interet ramblings, stick them below. And thanks again so much for watching, guys. We will see you next time. She’s rough around the edges, but she’s doing fine. Take her away, getting things to shine. That Bullnose Garage, she’s considered divine. Thanks again for watching. We will see you next time. Thanks again for watching. We will see you next time.

Hey folks, Ed here from Bullnose Garage. Sometimes, diving into the YouTube vortex can feel like a grind, so this week, I decided to keep things simple and share my latest project—a 1982 Ford Bronco that’s seen better days. But hey, one man’s rust bucket is another man’s desert crawler, right?

Meet the 1982 Ford Bronco

Say hello to my second Bullnose, a 1982 Ford Bronco I recently picked up from a friend. Now, she’s a far cry from my ’85 F150, which is destined for a full restoration. This Bronco, on the other hand, is packed with potential to become a rugged desert crawler. She comes with a manual transmission and, of course, the 4×4 setup you’d expect in a Bronco. It’s a bit of a fixer-upper, but that’s the fun part.

Rust and Repairs

This old girl has her fair share of rust—especially around the fender wells and tailgate. The previous owner was likely into mudding, which tends to trap grime and moisture in all the wrong places. The tailgate is a goner, but thanks to the wonders of reproduction parts, that’s an easy swap. The rear window motor is shot, so the elements have had free rein inside for a while. But hey, that’s what makes it a project truck, right?

A Desert Crawler in the Making

Living in the desert Southwest, turning this Bronco into a desert crawler is practically a no-brainer. I’m planning a modest 4-inch lift with a 1-inch body lift, along with beefier tires. Under the hood, she’s got an inline-six that, surprisingly, runs like a charm. For now, it’s staying put. The NP435 transmission is a keeper too—it’s as bulletproof as they come and perfect for a desert runner.

Tackling Unique Challenges

Adding A/C to this non-A/C truck is on the to-do list. Let’s face it, the desert heat doesn’t play nice. I’ve got a dash from an A/C Bullnose that might come in handy. Installing A/C in a truck that never had it will be a challenge, but hey, who doesn’t love a good DIY project?

Under the Hood and Chassis

The engine purrs like a kitten once I manually feed it fuel, so there’s some detective work to be done with the fuel line. The brakes are shot, which isn’t a surprise. I’ve got a brake job series already, so no need to rehash that. The Borg Warner 1345 transfer case and Ford 9-inch rear end are solid, just needing some TLC to get them trail-ready.

Wrapping Up

So, these are the twins of Bullnose Garage—an ’85 F150 and an ’82 Bronco. Both have their quirks, but that’s what makes them fun. The Bronco might be rough around the edges, but with a little elbow grease, she’ll be tearing up the desert trails in no time. If you want to keep up with the chaos, make sure you subscribe and maybe ring that bell. I’ve got a 408 stroker build coming up too, so stick around for that.

Check it out above, and let me know what you think. Questions, comments, or just want to share your own project woes? Drop them below.


Bullnose Garage at YouTube

If you want more specific information on Bullnose Ford Trucks, check out my YouTube Channel!

For more information on Bullnose Fords, you can check out the BullnoseFord SubReddit or Gary’s Garagemahal. Both are excellent resources.

As an Amazon Associate, I earn from qualifying purchases. If you see an Amazon link on my site, purchasing the item from Amazon using that link helps out the Channel.