Ford Bronco 4 door version.

[Jurva]

I originally had one stock version and one Baja version with incorrect body. Then I recieved second Bronco as trophy, which had both bodies. Since I had three kits with three stock bodies and one with Baja body, I decided to make one to a 4 door version.

First step was to cut two bodies and combine them. I decided to make rear doors little bit shorter. After gluing the halves, I measured that body was lengthened by 3,3 centimeters. That was important measurement as it would be needed later.

Then the same measurement was used to stretch the frame. I used evergreen L profile and straights for the extra bits. I cut it so that the middle exhaust support would be moved back. More on that later.

Then it was time to cut the floor and door panels. Both floors halves had locating pins at the frame, so locating them was easy. Then it was matter of filling the hole with new floor bits. I made the floor to have same kind of foor space, as in front seats.

I had to use two door pieces per side. That means that I have to fabricate new door panels to the donor car. Door panels had locating slots, that were used to tell me correct lenght that I needed to make the cuts.

I also copied the shape of the front seats mounts and made couple more. Missing are seat belt things, but I added them later.

Afted that, it was time to focus on mechanical side. Lengthening of tailshaft was done using evergreen rods. For the exhaust pipes, I again used two sets. Locating slots for the exhausts came in handy. When I cut the pipes, rear section were placed on its place. Then I measured what th front needed to be. Only one section had to be added in between passenger side mufflers. I used part of that tailshaft.

I also added some floor strenghtening, frame support and body mounts.

Last big thing was to extend the roof using again donor kits roof. That one will obviously be a roofless racing version, since I've robbed stock exhaust, stock seats and stock doorpanels. Missing are the hinges, which I've added later. If you notice, the roof seems to be lifted a tiny bit. I later cut 1 mm from the windshield frame. I made the wheels arches bigger, to house Baja wheels. I also found some flares from my parts bin. I don't want to glue before the paint, since they will be diffent color.

Now it's time to fill the gaps and sand. I used tamiya epoxy putty on the roof, because I don't want the putty to shrink. Middle of the roof needs alot of filling, because otherwise it would have a nasty dip in it. First sanding was done with 80 grit. Then I used metal ruler the same way the carpenters use scrapers to finish wooden surfaces. There will be another layer of different putty so make roof smooth and the arch contistent.

I hope I managed to open my process a bit. Feel free to ask questions.

Edited May 31, 2022 by Jurva
Typos fixed.

[Zen]

Wow, very cool project!

[cheyenne93]

I second that!!

[stavanzer]

Neat! Looks like a Factory Concept.

[Chuckyg1]

This is looking cool already. The roof looks a little tall to my eye.

[Jurva]

1 hour ago, Chuckyg1 said:

This is looking cool already. The roof looks a little tall to my eye.

I agree with the roof. It isn't so bad irl. Its stock height in the picture, but I cut 1mm from windshield frame. 

[cobraman]

Nice project, cool idea.

[bisc63]

Very good work so far!

[Jurva]

Finally got the roof ready for paint. It took several coats of filler and filler primer to get it smooth. Wasn't easy to get it "straight" as it is roundish in 2 ways. Roof will be white. Body is TS-34 Camel Yellow.

 

[cobraman]

Nice work !  That is way cool!

[espo]

Great looking conversion. 

[Chuckyg1]

Coming along nicely. The roof looks much better now that the post has been added. Keep it coming.

[slusher]

Really nice looking Bronco.  That’s going to be very sharp..

[Jurva]

I made roofrack out of Plastruct profiles. The 1:200 rails were perfect for the sides. Then I just made the ends with 1mm round stock.

[slusher]

Nice touch on the roof rack!

[David G.]

What a great idea!

Excellent engineering and workmanship, it looks like it was meant to be that way.

David G.

[Jurva]

Some progress done here. Made interior carpet using embossing powder. I added two layers of it, and then painted it with Tamiya dark yellow. Collected some stowage for the roof rack and for interior. Some are 1/35 Miniart and Meng stuff. Other from various other kits. Made couple of bags from Tamiya putty. I will make resin copies for the future.

Edited June 21, 2022 by Jurva
Typos.

[espo]

Great looking body and chassis work extending the wheelbase. The roof rack is really realistic looking. 

[Jurva]

Well, got some casting done. Did some spare stowage for the future projects. Always have old molds, where to dumb extra resin. I'll give some of the greeblies to my friend, who likes to build weird stuff.

[Saltie Olds]

This rig is looking good. I’m liking it and can’t wait until i get to see the finished product.

[David G.]

It looks like you're adding a lot of interesting detail. Can't wait to see it all in place.

David G.

[slusher]

On 6/22/2022 at 5:45 PM, Jurva said:

Well, got some casting done. Did some spare stowage for the future projects. Always have old molds, where to dumb extra resin. I'll give some of the greeblies to my friend, who likes to build weird stuff.

Cool stuff!

[Raymond Gallant]

I like where you're going with this but I have one question, are you going to straighten the "C" pillar. Originally it had the same angle as the windshield but I think it should match the "B" pillar. No way a widow can roll up and fill that opening.

[Street Rod]

Great idea for a Bronco build. Your fabrication work looks really good and I like the extras for the roof rack. Keep up the good work!

[yh70]

she sure is looking great..i like what u have done so far..