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Custom Bronco Half Cab

drew707

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Thanks. That is good information. I don't know that I'll ever need mine to be certified in any fashion. I do intend on creating an internal roll cage (on mine) at some point so that should alleviate some of the concerns for structural strength.
You do all the proper welds and tie ins it’s likely going to be a-okay. But strictly on a legal front you’re on your own if anything happens of course. Repair shops nationwide perform identical repairs daily. Not making a scare tactic out of this by any means just saying once those pieces are touched outside of Fords assembly line they can’t measure it’s ability to perform the way it was designed is all


Also, I’m not a vehicle proctologist so I can’t say absolutely one way or the other. I just know enough to make me stupid.
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BigMeatsBronco

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You do all the proper welds and tie ins it’s likely going to be a-okay. But strictly on a legal front you’re on your own if anything happens of course. Repair shops nationwide perform identical repairs daily. Not making a scare tactic out of this by any means just saying once those pieces are touched outside of Fords assembly line they can’t measure it’s ability to perform the way it was designed is all
Yeah , I'll use 4130 and form pin-on inserts with a bolt together flange for rollbar reattachment. And a cross brace for when it's removed.
Aircraft grade stuff only.

I'm not the lawsuit-happy type, so ford don't need to worry about legal issues from me.
 

Chrome_Pony

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Incredibly interested in a bolt on half-cab option for a 2-door!

My wallet is ready
Hahah, the Halfcab mod potential is the only reason I'd want a 4DR.


A Scrambler-style LWB Bronco?

HELL. YES.

Ford Bronco Custom Bronco Half Cab 1648147701011


Ford Bronco Custom Bronco Half Cab 1648147789732


Ford Bronco Custom Bronco Half Cab 1648147769644


Ford Bronco Custom Bronco Half Cab 1648147665450


Ford Bronco Custom Bronco Half Cab 1648147633050
 

Min_Ahn

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Ugh I wonder where this is heading..
 

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flip

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Each manufacturer publishes position statements, metal repairability charts and repair procedures. Like I said earlier, Ford just bought back a 2020 Explorer because their repair manual was wrong and frame section couldn't be replaced according to their instructions (boron).

"Boron and Ultra-High-Strength Steel/Martensitic components must be replaced at factory joints; sectioning is not allowed"

If you buy a vehicle and modify, it's your business. If you start cutting around on stuff and compromise safety or vehicle integrity, that can get into a whole different liability issue and might void the vehicle warranty. This isn't like running a hot program or putting bumpers on. There are published procedures on how to safely and correctly do repairs on different parts of vehicles for a reason. Just sayin'.
 

MaverickMan

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What am I missing here? Everything is welded together. How is a sawzall not come into play here? You're dealing with boron steel, HSLA steel and bake hardened steel in the horizontal bar, rear down tube and cross reinforcements. No bolting here, it's going to be cut and weld and there is no procedure to weld on boron without screwing it up.

Ford Bronco Custom Bronco Half Cab 1648147633050
Just a thought here, if its all welded together how is there no welding process to weld it?
 

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billybong420

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By taking out the roll bar you are losing structural rigidity how are you making up for that? Also what about the side airbags?
please, please, everyone, let's not focus on the details here, let us let this man rip apart his perfectly awesome vehicle.... hell be damned with safety items, or rigidity mumbo jumbo.

sir when you have this completed, i will fly wherever you are so that when you go to take the first jump with it and you yell, "someone hold my beer" i will be there for you! i will hold said beer and watch you fulfill your destiny!
 

Seatmandan

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By taking out the roll bar you are losing structural rigidity how are you making up for that? Also what about the side airbags?
The Boron Steel roll frame serves MANY purposes on the BIW of this vehicle, other than framing the glass and housing the airbag curtains. Good Luck to the OP with the longevity of the vehicle.
 

Seatmandan

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please, please, everyone, let's not focus on the details here, let us let this man rip apart his perfectly awesome vehicle.... hell be damned with safety items, or rigidity mumbo jumbo.

sir when you have this completed, i will fly wherever you are so that when you go to take the first jump with it and you yell, "someone hold my beer" i will be there for you! i will hold said beer and watch you fulfill your destiny!
This comment made my day. Very well said, sir.
 

flip

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Clubs
 
Just a thought here, if its all welded together how is there no welding process to weld it?
Only where Ford says you can spot weld and they also give you a specific wire type, size and nugget size depending on what steel it is. My point posting is not dissuade the OP, just make them aware there's a lot more involved to do these modifications and try to provide some useful information. The days of just welding on something and calling it good are long gone. As a dealership with a body shop, we do the repair by the book or not at all. Way too much liability involved with doing a half-assed repair.


General Specifications


ItemSpecification
Plug Weld hole8 mm (0.315 in)
Weld Wire ER70S-30.9 mm (0.0354 in) - 1.1 mm (0.0433 in)
Weld Wire ER70S-60.9 mm (0.0354 in) - 1.1 mm (0.0433 in)




Weld Nugget Chart


Test Thickness of MetalNugget Size
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in)4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 0.7 mm (0.0276 in) + 0.7 mm (0.0276 in)4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in)4.7 mm (0.185 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 0.9 mm (0.0354 in)4.7 mm (0.185 in)
1 mm (0.0394 in) + 1 mm (0.0394 in)5.2 mm (0.2047 in)
1 mm (0.0394 in) + 1 mm (0.0394 in) + 1 mm (0.0394 in)5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in)7.1 mm (0.2795 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 2 mm (0.0787 in)7.1 mm (0.2795 in)
3 mm (0.1181 in) + 3 mm (0.1181 in)8.7 mm (0.3425 in)
3 mm (0.1181 in) + 3 mm (0.1181 in) + 3 mm (0.1181 in)8.7 mm (0.3425 in)
3 mm (0.1181 in) + 0.7 mm (0.0276 in)4.3 mm (0.1693 in)
0.7 mm (0.0276 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in)5.2 mm (0.2047 in)
2 mm (0.0787 in) + 2 mm (0.0787 in) + 0.7 mm (0.0276 in)4.3 mm (0.1693 in)
0.9 mm (0.0354 in) + 0.9 mm (0.0354 in) + 2 mm (0.0787 in)4.7 mm (0.185 in)
2 mm (0.0787 in) + 0.9 mm (0.0354 in) + 1 mm (0.0394 in)5.2 mm (0.2047 in)
1 mm (0.0394 in) + 3 mm (0.1181 in) + 1 mm (0.0394 in)5.2 mm (0.2047 in)
3 mm (0.1181 in) + 1 mm (0.0394 in) + 2 mm (0.0787 in)7.1 mm (0.2795 in)
0.9 mm (0.0354 in) + 0.7 mm (0.0276 in) + 0.9 mm (0.0354 in)4.3 mm (0.1693 in)




Ford Recommended Steel Repairability Matrix


GradeTrade DescriptionsWelding MethodCold RepairsUse of Heat for RepairTemperature RangeMaximum Heat
MAGSqueeze-Type Resistance Spot Welding (STRW)MAGBraze
Mild SteelMildYesYesN/AYes aYesUp to 650° C (1,200° F)90 seconds x 2
Laminate SteelQuiet SteelNoYesNoYes aNANANA
Bake Hardened Steel (BH)Bake Hardened Steel (BH) 180, 200, 210, 220, 250, 280YesYesYes bYes aYesUp to 650° C (1,200° F)90 seconds x 2
Solid Solution Strengthened-YesYesYes bYes aYesUp to 650° C (1,200° F)90 seconds x 2
High-Strength Low Alloy (HSLA)High-Strength Low Alloy (HSLA) 200, High-Strength Low Alloy (HSLA 250, High-Strength Low Alloy (HSLA 260, High-Strength Low Alloy (HSLA 300, High-Strength Low Alloy (HSLA 340, High-Strength Low Alloy (HSLA 350, High-Strength Low Alloy (HSLA 500, High-Strength Low Alloy (HSLA) 550YesYesYes bYes aYesUp to 650° C (1,200° F)90 seconds x 2
Dual Phase Steel (DP)Dual Phase Steel (DP) 500, Dual Phase Steel (DP) 600YesYesYes bYes aNoNANA
Dual Phase Steel (DP)cDual Phase Steel (DP) 700, Dual Phase Steel (DP) 900 and Dual Phase Steel (DP) 1,000Yes dYesYes bNoNoNANA
Ultra High Strength Steel (UHSS) (Martensitic, Boron)eBoron, MartensiticYes aYesYes bNoNoNANA
Transformation Induced Plasticity Steel (TRIP)Transformation Induced Plasticity Steel (TRIP) 590, Transformation Induced Plasticity Steel (TRIP) 780, Transformation Induced Plasticity Steel (TRIP) 980NANANANANANANA

aCold repairs can be performed if damage excludes kinks. May section only if approved procedure in workshop manual.

bMetal Active Gas (MAG) braze allowed for non-structural applications only.

cDual phase steels DP 700 class, DP 900 class and DP 1,000 class must be replaced at factory joints, no sectioning unless approved procedure in workshop manual.

dFor DP 900, 1,000 and Boron use Metal Active Gas (MAG) plug welding only, no stitch welding.

eBoron and Ultra High Strength Steel (UHSS)-Mortensite components must be replaced at factory joints, no sectioning allowed.
 

Seatmandan

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Not really. Remember, the Bronco is a body on frame construction. The chassis/frame provides the strength and overall rigidity. The roll bar does provide structure to the body shell. The body to frame mount is cushioned by rubber body mounts to isolate the body from the frame.
Sorry, but this is just not true! These comments make me laugh. It is true that unitized body-constructed vehicles are engineered such that the body IS the entire structure (monocoque, such as an airframe) in modern day BOF engineering, the two systems WORK TOGETHER to achieve optimal torsional rigidity, strength and integrity of the vehicle. Drastically altering the body portion of the system WILL ruin the vehicle. Good luck.
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