Be sure to mount Steel Floor Plates under them as well. Remember to space them away from body. Once correct, tack weld to hold them in place. Now that the Interior Bar has been completely tack welded together, carefully put the hard top back on and check your work.
Make sure that it all clears. Remove the hard top and weld the bars together so it can be removed from the vehicle without breaking apart the spot welds. Remember to weld on the lower pads. Drill holes for the mounting plates. Be sure to look what is under the body. Try not to drill through a body seam or close to one, look out for the fuel tank and filler hose. Remove the Interior Bar assembly from the Bronco. Once out of the vehicle, take the time to weld up all seams.
You can now primer and paint or powder coat the interior bar. Please note, a normal bikini top will not fit these bars. Remove the mounting bolt that holds the E-brake to the dash. Leave the two mounting bolts that attach it to the firewall in place. Pivot the e-brake assembly towards the passenger side enough so that you have adequate room to depress the pedal.
Call Us Your Account Your Cart Checkout. Once everything is aligned correctly, tack weld the hoop to the floor plates… Repeat this step for the Rear Hoop behind the seats. E-Brake Fitment Instructions 1. Mark and drill a new mounting hole in the dash and mount the bolt in the new position. Smittybilt purposely supplies these bars a few inches long so they can be trimmed to each specific truck. The easiest way to accomplish a proper fit is to concentrate on just one side. Take the time to make that bar fit perfectly and then use it as a template when cutting the other side bar.
This is especially important with the "fishmouthed" cuts. Before any cuts are made place one side bar roughly in the position it will eventually be in. Then hold the rear of the side bar up near the spot where it will intersect the main roll bar. Once you've determined the side bar is level make note of how much higher the horizontal of the side bar is than the horizontal of the main rollbar.
This is approximately the amount you will need to cut off the end that attaches to the floor. However keep in mind that if you're attaching the side bar to the rear bar in the middle of the radius it will be slightly lower.
And if the rear bar is a larger diameter as mine was the side bar will be even lower. This can make quite a difference in final placement if you forget it. Making the "fishmouth" cuts just takes a careful eye. Try to hold the side bar up against the roll bar near the radius.
One way of finding out where the side bars should intersect the rear bar is to measure the spreader bar. The distance between the side bars should be approximately the same at the front as it is at the rear. The hinges and latch need to swap positions so that the hinges are on the new bottom and the latch is on top. Luckily there's enough metal on both top and bottom to make this work. The lip on the old latch side the new bottom is too wide for the hinges and needs to be trimmed out as shown.
The side to the left of the latch has not been trimmed and the side to the right has. Then holes need to be drilled for the latch and hinges. If you centered your cut top to bottom then everything should work well with just the factory play in the hinge and latch screws I wasn't quite centered so I had to enlarge some holes After welding the frame back in, grinding down all the welds, using a little bondo and repainting it, I realized that I really should have painted the whole dash.
And since all the bezels on Bronco dashes are almost impossible to mask off, I took the whole dash out to paint it. If I had known I was going to take it off I would have welded it from behind and made my life a lot easier! I suppose that's how working on a Bronco is sometimes. So here's the finished product. The new glove box position will work out well I think. It keeps full use of the box, door and hinges and puts the speaker grille behind the roll bar where it really does about as much good as it did in it's stock location.
Now that the glove box problem is taken care of it's time to install the actual cage.
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