Welding stuff for my sis' '68 Bronco

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Heya folks! Haven't posted on here in a good while. Done a few small projects here and there, but recently was a bit busy doing some stuff for my sister's recently acquired '68 Ford Bronco. She picked it up over the summer and I spent my summer weekends and this past Christmas break helping fix it up for her to take back down to SoCal with her this year.When it arrived home (the holes in the concrete are for a 2 post lift I was installing at the time):A lot of the work on the vehicle was pulling it apart and putting it back together, with a lot of stuff going off to get powdercoated white (wheels, roof, rollcage, etc). I also installed a power assist braking setup and power steering, amongst other things.The roll cage (which I've got to look for photos of ) was a real pain to assemble, since they shipped it welded together at odd angles "so it wouldn't fall apart while shipping"... which is odd cause it was taped and wrapped to all hell and back. Once that was ground apart, I set it where we wanted it, cut off the excess, and went to town.The other, 'lesser' projects involved making a custom mounting setup for some side steps and a whole new tow hitch assembly.The side step assembly was relatively easy. There was nowhere along the rocker panels to attach them directly, and with the aux gas tank on the driver side, I couldn't exactly weld it right in place. The solution was to make that bracket assembly to bolt the steps in place, then bolt that at multiple spots along the rocker panels where we had some access to stronger metal.The bigger project was to make a custom tow hitch. I'd already customized the one that came with the vehicle, but the addition of a larger main gas tank meant it wouldn't fit.The solution was for me to custom make one that would fit in the brackets, between the bumper (which uses the same mount points and bolts) and the gas tank / guard, but still provide a solid setup.The end brackets clamped together and getting started:This was made of angle sections cut to length and then a spacer fit between them. From there, a strap piece would drop down to a cross bar where the hitch receiver would be attached.The other end of the crossbar after the first strap end was connected to it. Just a rather amusing 'smokin' shot:Everything but the receiver piece put together. The U sections are large heavy duty U-bolts that have had the threads cut off and then they're welded in place. Plenty of weld around those are they're where the chains attach to and are the 'backup' should the hitch ever fail.Everything together and the hitch set in:All the welds on the setup were gone over two or three times to ensure there was plenty to hold it together and no gaps or weak spots remained. All this was done with my Lincoln Electric MIG welder. The vehicle's already towed a large U-Haul trailer down to SoCal so I can say with confidence that it all worked out. As soon as I can find some shots of it I'll post up images of the roll cage as well. That turned out pretty good as I did some custom wiring of overhead lights and speakers that ran through the cage instead of outside of it.
Reply:That's a very nice Bronco!   Broncos are my favorite classic Ford.  Nice work on the hitch and step bars.  I'd like to see your cage too.   I've had my 69 Bronco about 20 years now.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:She must have paid a fortune for a Bronco in that good of shape.
Reply:Nice looking Bronco. I'd like to see picts of the cage as well if you find them. I have a few reservations about the tow hitch. It's certainly not built the way I would have done so. I also question the look of some of your welds. I can't see them well in the picts, but they look a bit rough so I'm thinking they may be a just bit cold. With out good weld picts I can't really say one way or the other so I'll reserve judgment. My big concern is with those U bolts. I know from experience fixing tie downs others have done on trailers and truck racks, that they probably won't stand up to the weight of a medium sized trailer (5K) jerking hard on them. There probably isn't enough weld area to keep them from ripping out. If you had thru drilled the tube and then welded top and bottom they wouldn't go anywhere until the rod failed. Another option is to have used the medium weight weld on tie down loops that are sold for trailers. They are usually good for 5K each. The good thing is that I doubt anyone will tow anything heavier than a 3.5K-5K trailer with that vehicle..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:I hope that the reciever is tied into the frame again back under the vehicle where we can't see it so it is connected at more that just the end of the frame.  Anmy htches I have been involved in installing have more that 1 connection point.  If not, good luck
Reply:You would probably be wise to ditch those u-bolts fast.  Not only are they "iffy" for safety chains, but im betting at some point someone will try and use them as tow points which isnt going to last long at all.Have we all gone mad?
Reply:Nice truck!heres mine (work in progress)...we should make a Bronco section lol