10x02 - We've Gone Plaid

[bunniefuu]

Please email Dave at...

[David] So, you know,
now it's kind of the
Ford v Ferrari

-kind of scenario, right?
-This is bad.

I see some bad spots.

I see some okay spots.

Probably get bolts out
of the Titanic easier.

Let's make a BB out of
this thing.

[Dave] Yeah,
I think this thing
will be really pretty quick.

-You know what a BB is?
-No, what's a BB?

-You have to be here at least
another year before you start.
-Oh, okay.

-Telling me
what color to paint.
-[bleep] brown.

-Look what showed up.
-I'm stoked.

I mean, I think
they fit great.

I'm sure Dave will come up
with a color,

if he ever shows up today.

Oh, he's not coming?

[Dave] When I look at
a blank canvas, I see
endless possibilities.

As the ideas come to mind,
the lines start to fall

into place.

And before you know it,
we have a bitchin' ride.

A bitchin' ride has
intense color.

This is gorgeous.

Performance.

[man] It's fantastic.

[Dave] Stance, wheels, sound.

There's one thing that makes
our cars stand out.

Ours are bitchin' rides.

-Well, it never gets old.
-[man laughs]

So we happen to be out here
hanging out in Arizona,

and I wanted to come up
and hang out for a few minutes

with our good friend
Dave Jones and talk to him

about potentially
another vehicle.

-So you got
the collection. Ooh.
-Oh, yeah.

-Two of my personal favorites
right there.
-So... yeah.

So in Dave's man cave,
it is super rad.

He's got the perfect mixture
of supercars, trucks,

Corvettes, one of which,
the truck and the Corvette.

Well, you've already
seen that.

But my point is, on the walls,
all of the cool stuff in here,

it's something to see.

I still love this one.

Don't tell any
of the other CF1 owners,
but this might be my favorite.

[David] I'm not saying
anything about it.

Everybody always tells me
"that blue one's pretty."

So I'll just leave it at that.

We'll just leave it
right there.

Oh boy, I'll tell you what.

All the CF1 owners have
got the best car, right?

[laughs] Yep.

-But this one in particular,
right at the moment...
-Yeah.

-...happens to be
the very, very best.
-Yeah.

And the GMC, it looks like
it's doing really well.

-[David] Yeah, GMC it's, uh...
-It's beautiful, as always.

It still gets a lot
of attention

when I bring people over.

But see now,
you got some other stuff

in here that's pretty cool.

So I picked this up about
three years ago,

had about 7,000 miles on it.
I always wanted a GT.

-Since last year, this is
the one I bought last year.
-Awesome.

-F8?
-[David] Yeah.

Oh, yeah.

So now it's kind
of the Ford v Ferrari

-kind of scenario, right?
-I like that.

[David] I kind of... put them
back there together,

and you've got the Ferrari.

Obviously, it's two different
breeds, right?

-Oh, sure.
-But it's kind of cool.

But it has a good heritage
to it.

-Yeah, yeah.
-That's awesome.

These are beautiful.
I've always been such
a big fan

of both of these cars, too.

This is the first one
that I had built.

-Oh, it is?
-It was 1956.

-Okay, yeah.
-It's got a Coyote in it.

[Dave] Very cool.
Built locally?

-Yeah.
-Nice.

Yeah, it was built by a local
builder here in Mesa.

Awesome. That's good.

I love the brown.

Yeah, well, I had one of these
when I was a kid, too.

-Did you really?
-Yes.

And it was root-beer brown.

It had a big old Chrysler
motor in it.

And so I used to go buzz
the streets on that at night.

-Picking up chicks.
-Yeah, picking up chicks.

Let me guess.
Did it have gold velour
diamond tuck and roll?

Uh, no, I don't think
it had that.

Really? You were missing
the boat, buddy.

-Well.
-[both laughing]

This one.

-Now, this one--
-I super love this.

I'm very familiar
with this car.

-I know you are.
-Yeah.

I just absolutely love
the body style of a T-Bird.

This one's been modified,
obviously, very heavily.

Well, the stuff that
they've done to it,

I just really love this one.

[David] Yeah, this one's what,
a 2012 regular runner?

-[Dave] Yep. Yep.
-[David] Yep.

And it's just a gorgeous car.


-Yep.
-Yep.

Color combo's beautiful.

I love that tobacco
and graphite.

I think it's just beautiful.

-Very simple and clean.
-[David] Yeah, it is.

Yeah, this is a beautiful car
right here,

but I'll tell you,
if I had to take my, uh...

-You'd probably take...
-I'd probably go with
the SF90 or the GT.

-Do you think you'd probably
go with that one instead?
-I don't know, I mean...

Dave definitely has
a lot of everything
in his collection,

but there is
one thing missing.

You had me come up here
for a reason.

You wanted to talk to me
about a Bronco?

-Yeah.
-Is that what
you're talking about?

Yeah, so I picked up
a '68 Bronco,

and, you know, I've always
been pretty fond of those.

And my buddy had it,
and he wanted
to get rid of it.

So I picked it up.

And so I was thinking maybe
we could do something

-and see what we could do...
-Sure.

...about putting
something together.

When I was younger, I always
had a Bronco to drive.

My buddy says, "I'm going
to get rid of this Bronco."

So I decided I'd go ahead
and pick it up.

And I just always wanted
to get one going.

Yeah, we could definitely
do something like that.

You kind of have an idea
of what you want to do

-as far as how big of a build
you want to...
-Well, I probably

want to go get
a roadster shop.

I've had it for a couple
of years, and it's just time

-to either do something
with it or, you know, move on.
-[Dave] Right.

-Okay.
-But I want to do it up right.

So maybe we'll do a Coyote
in it, something like that,

-because I know they make
plenty of stuff for those.
-Yeah.

It was part of my childhood,
and my dad always had them.

We used to always
go hunting in them,
and they were just our,

you know, kind of
our family thing.

Well, you know,
the Bronco has a big history

with me because
when I was a kid,

even before I was driving,
my dad always had a Bronco

and a Jeep.

-Okay.
-And so we'd go up with
the families

and go do hunting
together and always
doing four-wheeling.

And so the Bronco
has just always been kind of

a big thing in my life.

Sure. Sure.

So Dave grew up with
Broncos in the family.

His dad had them.
They went hunting
all the time.

He had one in high school.

So when he got the opportunity
from his friend to buy

another Bronco
and he wanted it built,

when he asked me to do it,
well, I was totally in.

-To the romance
of that childhood.
-Bring that childhood back

-a little bit.
-Right.

-Yeah, exactly. That's funny.
-Like, I need a little
more childhood in me.

-Don't worry.
I'll steer you down--
-Just another...

Just another toy.

-Just another toy in the barn.
-Yeah.

No, I'd be really excited
to put something together
for you.

-Okay.
-It's going to be great.

What's missing is
I don't have a Bronco,

so I think that would probably
fill out the collection.

Just put some creative juice
to it and get it flowing.

That's my specialty, Dave.
It's going to be a lot of fun
to work on that Bronco.

-All right, yeah.
-I look forward to parting
the seas,

and we'll part one more
big one in here.

-How's that?
-[David] All right. Yep.

We'll have to move it around
a little bit.

[Dave] Right.

So I've got a pretty good
handle on what Dave's

looking for
in this Bronco build.

So I'm going to get
back to the shop,
do a little bit of renderings,

and put it in front of him
and see what he thinks.

Cross-training is the name
of the game today,

so we're going to put
Kyler with Roy

to tear this old Bronco down.

This should be a good
training experience.

With any good tear-down,
we got to take care of

the big parts
and the little parts.

These little details will
really help go back together.

This also gives us
the opportunity to know what

we have to work with
and what we're missing.

Probably get bolts out
of the Titanic easier.

"I'll never let you go, Jack.

Jack!"

Been together a long time.

Don't worry about me.

Well, most of the bolts
were taken out of it

or snapping off.

But at least
they're coming out.

This is going to need
all-new hardware.

Get that piece of crap
out of here.

Everything is rusted.

[Dave] And the more
we tear down
and the more we dig into

-this particular vehicle...
-This is bad.

...the more we find out
there's some
good history here,

there's some pretty good
rust as well,

and some cool trinkets.

You know, it kind of looks
like it's raining rust.

On Roy, at least.

Nice.

There you go.

[Dave] You know, this is
an extremely dirty job.

I feel that I need to lift
some spirits here.

-[Roy] Hey, dude.
-What's up, brother?

[Roy] How you doing?

Great, now that I see you.
You made my day.

-So I got that going
for me, then.
-Yeah, that's it.

Is that it?

You know, he's doing
a great job,

and I really
don't want to get dirty,
[snaps fingers] so I'm out.

Kyler's helping out,
but he needs to be kind of
careful here.

This dash is so small that
I can barely see behind it.

Okay. Pay attention.

This is why Roy is here.

He's seen everything.

Paying attention.

You cannot remove one of
these ignition switches

unless you have the key.

On a lot of them.

-First basis of all of it.
-Turn the key to accessory.

You know, these youngsters
can really learn something

from us old-timers.

This whole car is
like a puzzle box.

Yeah, you roll it over,
past accessory,

pulls right out.

You bag this.

You actually need
the key for this part

to actually remove
the tumbler.

[Kyler] I wonder what
they were driving this in.

You think it's gross
on the outside,

you should see
the inside of it.

It's real tight.

[Roy] Okay, it's going down.

[Dave] On these
first-gen Broncos,
they had an option,

or maybe it was on
all of them, that they
had two gas tanks.

We're going to reduce
that down to just one

and keep it simple.

[Roy] Do the other side,
then we're going to start

taking the body bolts out.

There we go.

Awesome.

[Dave] We're about there.
The chassis looks awesome.

And now we're going to send
the body out, get it dipped,

and see what it looks like
when it comes back.

I see some bad spots.
I see some okay spots.

I don't know.
I think we'll be okay.

These are pretty basic.
There's definitely some rust

that we're going to
have to repair.

I mean, you can see stuff
like this, stuff like this.

But I don't think
it's too big of a deal.

These aren't put together very
complex, so we should be able

to cut out what we need to cut
out and replace it with new.

No big deal.

So as soon as we get
everything onto this thing,

we're going to send it
up to dip.

[Dave] Back in 1968,
if you had a Bronco,

you didn't blow kisses at it,
and you didn't just drive it

to the office and back.

You actually took these things
out and used them.

So we're expecting to find
some rust, which we have.

We might be expecting
to find a little bit
more rust,

which we haven't yet.

But you never know
until it comes back.

[Kevin] For this,
we have a Coyote 5.0
and a brand new chassis.

So none of that will get used.

We're probably just going
to send that...

What do they say,
up the river?

So if you know anybody
that's looking for
a Bronco chassis,

please email Dave at
"Dave at..."

[laughs]

[Dave] Now that the Bronco's
back from blast,

we're going to go ahead
and take a good hard look
at it,

see what needs to be replaced,

and see what
we can simply repair.

Oh, we got her back, huh?

It's few and far
between if you find a car

that has zero rust,
zero damage over
the amount of years

that it's been on this planet.

[Kevin] Uh...

There's obviously some spots,
you know.

Oh, we got her back, huh?

We're in the midst
of a kick-a*s
'68 Bronco project

for our good friend
Dave Jones,

and it's just back from blast,
and I think we might have

some good news.

Yeah, I was just taking
some parts out

so I could see the floor
and a couple things.

I mean, we definitely have
some clean parts.

I mean, the hood's beautiful,
the grill's beautiful.

Uh...

[Dave] Dash looks beautiful.

[Kevin] There's obviously
some spots, you know,
just a handful.

-Just a handful.
-[laughs]

There's a handful
of bad spots.

The fenders aren't horrible.

I mean, they do have
some here and here.

We'd rather run
an original fender, right?

-If we can.
-Okay.

I think the biggest
thing on this is

we definitely want
to look it over

and really just try
to calculate our man hours

versus a new one.

[Dave] Anytime you can keep
the original sheet metal,

it's more preferred.

We're expecting the worst,
but I think we actually got

something pretty good.

How's that one look?

Not bad?

-It's not as bad
as the other one.
-Not horrible.

Oh, yeah, I remember this one.

Oh, this is the one
that got shot with a shotgun

-from this side.
-[Dave] From the back side.

"Honey, my g*n went off
in the cabin."

Looks like it might
be peppered

from, like, a .410 shotgun.

Not sure if it came from
the inside of the cavity

or the outside of the truck.

But either way,
we're going to go ahead

and replace that door skin.

So you can see,
like, the middle of the floor

is not horrible.

The floor behind
the wheel wells,

obviously, is just
a common spot.

It rots.

There's a little bit of rot
in the top.

You know, we'll have to look
at the rain gutters.

-Mm-hmm.
-Looks like there's
a little glue left.

The rain gutters
on the roof are absolutely
not salvageable,

so I think we'll go ahead and
replace the entire roof skin.

How's the sides look?

Uh, I mean, it had
that weird gas filler

-for the third tank here.
-Right.

And I think that
the same person that

installed the stereo
installed this, too.

-Yeah.
-So...

-Um...
-We're going to shave
all those anyway.

We'll do a different gas cap.

Yeah, and it looks like
this rocker is decent.

The other one has
a hole in it.

Most of the rust
on this seems like

to be from
the door jamb forward.

Or from the back of
the wheel well back.

We can get this front end done
and get these done

and then get the doors on
and, you know...

-Set it on the frame and start
fitting it around the motor.
-Yeah.

[Dave] You know,
definitely there's some
sheet metal work to do

on this thing, both structural
as well as cosmetic.

We're going to go ahead
and put our new guy,
Jake, on it.

He's kick-a*s.

Uh... And let's make a BB
out of this thing.

Yeah, I think this thing
will be really pretty quick.

-You know what a BB is?
-No, what's a BB?

What do you mean?

It's a Bitchin' Bronco.

Oh.

I'm going to do
a Porsche color combination

on this thing,

with the Porsche chalk
on the upper section

and the main body.

And on the lower section,
I'm just going to do simply

a Carrera white.

I think this will
just be a nice contrast,

nice clean two-tone.

I think it'll be very
interesting to just have it

as just a nice,
clean driver style.

But I think on the interior,
I'm going to suggest something

that's going to probably be
a little bit different

from what we normally do.

I think a black, maybe
we do it in a little bit
of leather,

do a little bit of Alcantara,

and then inserts of
this plaid, I think
it's just going

to be very classic
and timeless.

I'm going to make it
to where our fender flares
that we build

are actually going to fit
onto this thing.

I think it's going to look
really great.

And more importantly,
I think Dave's going
to love it great

because he can take it off
some sweet jumps

and not take out
the corner panel.

Kind of envisioning doing
black Alcantara

on the surfaces next
to this plaid cloth.

But it is actually
going to look really nice

on the ceiling surfaces.

And we'll do black leather
as borders, perimeters,

and accents.

I definitely think with
the Porsche Carrera white

and the Porsche chalk,
the color combinations

is very classic.

I think Dave's going
to lose his absolute

loving mind on this thing.

It is, well, bitchin'.

You know, it looks like
some of the worst damage
on the body

is actually on
the passenger side right
behind the rear wheel,

which looks like
somebody either got hit

by a tractor, rolled it off
of a cliff backwards.

Regardless, we're going
to go ahead
and get this repaired

and make sure that it lines up
with all the new body panels.

We're just going to cut
a new square, put it in,

weld it, hammer it, dolly it,
do whatever we need to do.

It's going to be perfect,
and we'll move on.

All of the surfaces
have to be prepped

and cleaned properly
before you weld them.

If Jake does his job properly,

you'll never know
there was a repair.

The Bronco is moving
along perfectly,
but right now,

we have a surprise delivery.

Look what showed up.

Look what showed up.

[Dave] Something shiny
and bitchin' just showed up,

so we're gonna go ahead
and interrupt Jake,

and I don't think
he's gonna mind.

Boom, baby.

-Well worth waiting.
-I am so excited.

The engine's already here.
We got a Coyote 5.0.

-[Dave] Yep.
-Ten-speed automatic.

It's their new plug-and-play.
Super pumped about that.

-Awesome.
-But look at some of
the features on this stuff.

Did you know it was going
to be this beautiful?

[Dave] I had no idea.

I mean, look, you got
reservoir shocks, FOX.

Look at these bump stops.

[Dave] What would you call
those bump stops exactly?

'Cause I see that
they're adjustable.

So there's not only adjustable
up and down,

but if it ever hits this hard,

-this is like...
-Impact.

It's like, yeah,
it's a gas-charged shock.

-I don't know the--
-I've never seen these
joints before either.

I don't know
the scientific joint name.

I don't know,
but they're so cool-looking.

You're sure telling me a lot
about something

you really have no idea
what you're looking at.

Yeah, because
I build low stuff,

-but this stuff
is really cool.
-This is really rad.

Look at these sway bar
links, all machined out

of aluminum and anodized.

I didn't ask for orange,
but whatever.

-Lock-in.
-Yeah, all Fords
have lock-ins.

[Dave] That's cool.
And a solid axle,
not independent.

-[Kevin] Yeah.
-[Dave] Which is kind of cool.

I mean, obviously,
like, for road driving,

independent's just
a little bit better.

But for what this is going
to be used for, I'm sure

that's going to do just fine
on the road.

-This is way cooler.
-This is gnarly.

Right, right. Yeah.

-Uh...
-You want to keep
the other chassis around

and we'll do the metal
repair on it,

so we don't... I mean,
this is all fresh powder coat
and done.

[Kevin] Yeah. You know what
I'm thinking is

I'm almost thinking
we might be able to work

on these side by side,
depending on how it works.

I might be able to put this
in the assembly shop

and let them put
the engine in...

-Mm-hmm.
-...let them
pre-wire the engine.

And then we'll bring
the old chassis back.

We'll set the strip body on it
and they can do

-all the rust repair
and get it to paint.
-Okay.

And then we'll just marry
the two and be done.

Rad.

Everything's ready to go,
and this is going to save us
a ton of time.

Cool thing is,
it came with a gas tank.

-Awesome.
-Came with headers.

-Awesome.
-It came with a transfer case.

-Awesome.
-It bolts right to

our 10-speed
automatic transmission.

-Yep.
-So we are going to be set.

We have a new member
to the fab team, Jake.

He's going to be handling
all the heavy lifting
on this Bronco.

I mean, you've gone through
the whole backside,

and we've got to take care
of all the little rust

-all through the back, right?
-Yeah.

We've still got
the quarters off.

We've got the whole nose
chopped off.

I mean, it's kind of
to a point where I guess

we start rebuilding.

Yeah, finally get to
put something back on

-instead of cut it out,
you know?
-Yeah.

Yeah, put stuff back on.

Rust repair season's over.

It's time for these
replacement panels.

And then that little
top cowl piece,

you're gonna probably
just have to flex,

but I have no way
to attach it,

and I don't really wanna weld
it in yet.

[Will] We gotta make
a little bit more room
in this tunnel

for this big ol' engine.

[Jake] And this should
stay right on top.

It's probably on there
good enough.

-We'll say so.
-[Will] Something in there
to stay.

So this chassis is complete
and ready, so we can set

the body on
and make sure it fits.

-We don't typically
do it like this.
-Yeah.

-But that chassis is done.
-Okay.

It's powder-coated.
It's, like, finished.

We need to take this body
and go fit it on the chassis

just to check
the tunnel clearances.

And what I want to do
is get the firewall

-all mocked up
on here anyways.
-Gotcha.

So you could move forward
and get it...

-fastened on here.
-Okay.

[Will] It ain't gonna matter.

We're still going to want
to reference the back of

-that firewall to the engine.
-Okay.

[Will] We have some
new exhaust, and plumbing,

and a giant
engine-transmission combo.

I'm really wondering how well
this is going to fit.

Okay, then eyeball
that front mount.

Yeah.

-[Jake] I can't see
the edge though.
-[Will] It's okay.

[Jake] It's not really
sitting right.

[Will] Well, set it down
tight right there.

Might be able to lift it up.

[Dave] We're working on
a kick-a*s 1968 Ford Bronco,

and there's a lot of
replacement and repair.

This is moving along
really nicely,

and it's gonna look sharp.

[Will] Okay, then, eyeball
that front mount.

[Dave] Now it's time to do
a final test fit

of all of the big parts,
so we're gonna put it back

on the chassis
and make sure everything

lines up properly.

[Jake] I can't see
the edge, though.

[Will] It's okay.

[Kevin] The rest looks okay.

[Will] Well, set it down.

[Jake] It's not really
sitting right.

[Will] The battery mount
right there.

So the battery mount's
in the way.

No big deal.
We just unbolt it.

Right there.

Yeah, we're just gonna have
to take that off.

[Jake] Just take it off?

[Kevin] You ready?

[Will] Okay.

[Kevin] I'm contacting
with the mount.

It's a little tight,
but it actually is, like...

right on.

What does this side look like?

This side's got a mile
of room compared to that side,

so we're totally good there.

Here, put a mark on there,
and we'll get that

little bit of room made
for that.

[Dave] Everything's
finishing up beautifully.

It fits awesome.

Now we're going to go ahead
and take advantage of the fact

that the body is on
the chassis.

We'll finish out all of
the last details,

such as the plumbing,
the air conditioning,
heating hoses.

So that's easy enough.

So we sucked down
the whole quarter

to match this body line.

[Dave] Jake's biggest job
here is to make sure

that he makes
these panels look like
they were all one piece

from the original vehicle.

And it left, like,
a gap up here.

So I got to pull the fender
back up so I can weld it.

Pain in the a*s, you know?

Feels real good on the knees.

[Kevin] So in this situation,
replacing quarters
is just better.

There's kind of a little bit
of rust here,

a little bit of rust here.

We could do 10 patch panels,
or we could just replace

the quarters in one shot.

We've got the panels
temporarily in place.

Any way we seem to move seems
to cause a problem.

I'm gonna grab Will
so he can put his eyes on it.

I was just wondering about...
So this line, we gapped it

a little bit to match
the body line.

So I screwed the top in
to pull it up a little.

-Yeah.
-Just a little gap,

but it's sitting kind of flush
up here.

So do you think
it's good to weld?

[Will] Yeah, it looks fine.

[Jake] So I'm just looking at
this side where the gap is.

-You can still see it if
you look at the inside.
-Well, I know.

-I was just looking at...
-[Jake] You okay with that?

[Will] A little bit
of gap there.

But it's so tiny, I mean,
nature of the beast.

Obviously, we're going
to seam seal this.

I mean, if it comes down
to it, we're going to let it.

Just to have that enough gap
there where you're looking at

the weld is kind of
like, okay,

-that's not the way
it should be.
-Yeah.

But just like you're saying,
we're trying to keep some

-other dimensions that are
a little more important.
-Yeah.

It looks pretty good.
Everything's fitting
pretty well.

[Dave] Sometimes
the thickness of the new
body panels versus

the original body panels
can be quite a bit different.

In this case,
they're pretty close,

so I don't think it'll be
too much of a problem

to go ahead and do some
butt surfaces and make sure

we metal-finish them
out properly.

So let's just worry about
this core section,

the front fenders,
making this thing all

-super square,
nice and straight.
-Okay.

Then we'll tackle the roof.

Sounds good.

-Cool?
-Yep.

All right. Looks good.

So fixing here's and there's
is part of the repair.

It's just kind of part
of the game.

You know, all in all,
everything is going along

just fine on this restoration.

And you know what I always
say, it always gets real ugly

before it gets real pretty.

All of the panels
are going in perfectly,

but now we got to attack
something that's actually

a little too far
beyond repair.

We're going to have
to replace this roof.

Yeah, so I'm about
to drill all these.

I marked them all out.

I'm going to drill holes
for spot welds every inch.

They don't do it from
the factory, I guess.

They give you a repo panel,
so I got to take an hour,

mark them out, drill a couple
hundred holes, you know.

It wasn't horrible.
It was more this dripper
that was [bleep].

You had to pull the roof off
to fix it because

it was all underneath
and all rusty and [bleep].

[Dave] From the factory,
this area was actually
spot-welded.

And we do have
a spot welder,

but to be honest with you,
pre-fanning it

on and off again
and making sure that

we're lined properly,

I think what we're going
to do is fill weld this.

So we'll basically pop a hole
into one part of the bracket

and we'll fill weld that
to the new panel.

This will be a little bit
stronger than a spot weld

and a lot easier
for us to fit it.

Will's taking the old
roof home, though,

to build some redneck shack
or something.

He's like, "Save that
when you cut it off."

I was like, "Whatever
you want, man.

You're my boss."

All ready.

[Dave] Jake's one of our
new additions here

in the metal fab shop,
and he's doing
a wonderful job.

And now it's my turn to go see
how Jake's doing.

-That's my bad.
-You're gonna plug weld
all of this?

You're gonna
plug weld all of this, right?

[Jake] It gets a huge,
[bleep] eight-inch thing
of seam sealer, right?

Exactly. We're just gonna
put a self-leveling

seam sealer in there.
You'll never see it.

Sweet.

[Kevin] So we have Jake,
one of the new guys,

working on the roof
of this Bronco.

He's kind of been dealing
with Will on this deal.

But now we're going
to bring Dave in.

There's one little wiggle
on that, right above

the driver's-side vent glass.

Just a little flare-out,
see the last six inches?

You know, from time to time,
I like to check in with

the fellas in the shop,
and especially the new ones.

Just the drip rail, right?
Not the store scale.

-Just the drip rail.
-Yeah.

I don't think
I was scary at all.
I'm certainly not mean.

The bottom of the rail looks
pretty damn straight.

Just a little bit more.

Dave seems happy.
That makes me happy.

Right there, yep.

I'm probably just going
to throw a square on here.

Looks great, man.

I think you just paint
the whole thing gold
and silver.

Oh, boy.

Now he's going to run
some ideas past Dave.

Okay, Jake, you're new here.

We love you, but we don't need
any more cooks in the kitchen.

I'll be the designer.

You have to be here
at least another year
before you start...

-Okay.
-...telling me what color
to paint.

[bleep] rattle can black.

Yeah, right, right, right.

But I do appreciate
your input.

Yeah, I think, man,
I'm looking at it right now.

It looks square enough to me.
I mean...

I don't need Will.
I got Dave to be my boss.

[Dave] We're putting
a new roof on this Bronco,

and, you know,
even though Jake

wasn't really expecting
my visit,

I think he's doing
a great job.

He's doing a wonderful job,
actually.

Just go around
and zap, zap, zap, zap.

Three hundred and sixty times,
that's how many holes
there are.

[Dave] This has been
Jake's first project,

and to be honest with you,
I think he's nailed it.

The guy is
an awesome listener,

he does a great job,
and he actually follows up

on things,
and he's concerned with it.

And that makes
a great employee.

[Jake] That's about it.
Just go around.

We don't have to grind
these either, because

they get a big old
weather-stripping seal

that's self-leveling
and covers it all,

which is nice, 'cause grinding
in that crack sucks.

I did it when I had to take
the old one out, so...

[Dave] You know, we actually
have a fun problem here.

We have a huge space and a big
wheel and tire to figure out.

All right, you got her
on there?

-Yeah.
-Sweet.

Hey, that looks good.

I like it.

For a vehicle like this,
which is quite a bit different

from the other vehicles
we do at Kindig-It Design,

which are typically lowered
with big wheels,

this one's lifted.

We're going to put
a much bigger wheel.

But we want a good proportion.

We want some good travel room.

But we don't want it to look
like a monster truck.

Well, anytime you're building
a custom vehicle,

and especially when it has
a custom chassis,

you basically have
to go through
and get the offset.

Basically, that tells you
where the wheel's going

to sit in the side of the car.

You know, too far in
is going to obviously rub

if you're going through
a gutter.

And certainly, on a four-wheel
drive, you're going to have

a lot of opportunity
to articulate the suspension.

And on these axles,
they will kind of kick in.

So you've got to make sure
you've got enough
clearance for that.

I'm going to go
ahead and design

a wheel that looks kind of
like an original hubcap

for a Bronco or
an early Ford truck.

So a 17 is what we're running.

-315, 70, 17, right?
-Yep.

And this is set up to a 10.

So it's 11 overall, right?

Ten to the inside of the bead?

-It'd be 11 overall.
-Oh, 11 overall.

-[Will] Yeah, yeah, 10.
-[Dave] So 10.

-So 17 by 10?
-Yep.

-[Dave] Okay.
-And then it's, what,

-six on five and half?
-[Dave] Six lug.

-[Will] Six lug.
-[Dave] On 5.5?

[Will] Uh-huh.
Half-inch studs.

[Dave] Do you have hub length
and diameter?

-Diameter is 2.8.
-Okay.

The length is 0.326.
I'm stoked.

-I mean, I think
they fit great.
-Right.

I think this will be a really
nice-fitting piece.

And it'll look beautiful on
this very classic Bronco.

-So can we throw that wheel
on the front real quick here?
-[Will] Yeah, sure.

[Dave] And let's just
double-check turn radius.

One of the things I kind of
admire the most about
Broncos is,

well, they can use
my fender flares.

-Right.
-What I'm looking for
right here is to make sure

that the tread is inside
the fender line.

And I don't mind the side
bulge just slightly out.

That's how the back was.

So this is like
a perfect match.

-[Will] Yeah, it looks cool,
doesn't it?
-[Dave] Yeah.

And you're at full impact
right now?

-Yeah. So...
-Awesome.

The wheels are great.

So this diameter is... 3.5.

The overall length,
five and a quarter.

And that's right to the face
of your hub.

[Dave] Okay, sounds good.

Well, I'll go put this
in the design

and, uh, we'll move forward
with the custom wheels.

-Hell, yeah.
-Far out, man.

I know. It's cool, huh?

Thanks. Yeah.

-Awesome.
-I love the 4x4.

These are a set of fender
flares I designed.

They're 3.5 inches wide,
but have all hidden hardware.

It just has a very
classic look.

The flange is just
inch and a half.

[Dave] These are really cool
because they bolt in
from the inside

of the fender,
so you don't see
the sloppy hardware.

It just keeps the... when
you tighten the bolts down,

it keeps it from, like,
puckering up this
whole corner panel.

And then you don't need
washers either.

It's just kind of a big washer
for the whole flare.

[Dave] Jake has fabricated up
a flange that's like
a doubler,

and basically what this
will do is it goes on

the inside of both front
and rear fenders.

And this will help
structurally hold the skin

of the fender so it doesn't
wobble when you're putting

the bolts through
on the flares.

I'm also just right now
making a little
inch-and-a-half

piece of cardboard so that

I can trace
that yellow line down

and do my final cut
on the bottom corner.

[Dave] So how you build
a doubler panel is

you basically take
the backside of
the fender flare,

you take some chipboard,

and that's what Jake's
gonna do here.

He's gonna simply
trace it out, push
the holes through,

make sure everything lines up,
and cut 'em out of metal.

I got to make three pieces
just so I don't waste

the whole [bleep] sheet.

But just cut these three out,
you weld them together,

clamp it back on,
then you got to re-drill
all the bolt holes.

But other than that,
then you're done.

[Dave] Making a chipboard
template to ensure that

what we're going to build
is going to fit the project

is really kind of easy
in comparison

to making it out of metal.

Everything's lining
up beautifully.

Now Jake can go ahead
and weld this thing in.

So we have our doubler built.

We have all of the holes
lining up through the fender

into the fender flare
and the doubler.

Now all we've got to do
is drill the holes

and ensure they fit the car.

Jake's doing it exactly
the way we expect him
to do it.

He's starting out small
and working his way up.

This is a lot easier
to ensure you're not
gonna have

to start completely over.

We like to spray this
between the areas

that are getting welded
together to ensure

we got good coverage
and to seal the metal

so we don't have rust
popping through between
the two pieces.

Everything's looking awesome
on this project.

It's time to wrap it up.

Well, they're in, you know.

We're done.

[Dave] This has been a hell of
a couple of first weeks
for Jake.

Now it's time for us
to go down and check out

his progress
and see how he did.

You trying to hold
the truck up?

They told me to stand here.

Will making somebody nervous?

Nothing to worry about.

-It's just kind of how he is.
-So what do you think?

Are you trying to hold
the truck up?

They told me to stand here.

They didn't tell you
to lean on the truck.

[Dave] Basically, what Jake
is building is a washer

that will receive
the hardware to hold

the fender flare on
and spread the weight across

the entire panel.

Now it's time for us
to check it out

and see if it's actually
going to work.

[Will] So what do you think?

You know, it holds a lot
better with that plate.

I don't have to use
as many washers.

It keeps the shape of
this piece pretty good, too.

-Yeah.
-You can tie them
all down in a loop.

-Yeah, so it makes
sense, right?
-Yeah.

These flares are
working out great.

Jake's doing a great job.

Did you end up doing
these in quarters?

-They're three pieces.
-[Will] Three pieces.

-It's like one here,
one across the top.
-[Will] Yeah.

That's good and smart.
They're all tacked in place.

[Jake] Yeah, they're all...
They're fully tacked, ground.

-They're all welded on.
-Yeah, and the only gap
we're still looking at here.

I might build that slide now.

-I just don't want
to flex this too much.
-[Will] Yeah.

-[Jake] So...
-Yeah, I'd rather cut it
a little bit,

-cut the glass and move it
around than try to pull it in.
-Yeah.

Especially with fiberglass
because fiberglass
is super rigid.

Yeah.

But... it looks pretty cool,
so that's cool.

-We're kind of through
that stage, right?
-[Jake] Yeah.

[Kevin] One of our new guys
in the fab shop, Jake,

has done a knockout job
on this truck.

Well, we're on the, like,
last stretch of this truck.

[Kevin] Everything on this
Bronco's coming together.

We're just about ready
to wrap it up

and get to the body shop.

Dave is nowhere to be found,
but Dave the client is here.

-Hi, Dave.
-Hey, how you doing, man?

It's another day just trying
to get all these things done,

but I know it's been a while
since you've seen your Bronco.

What do you think?

Well, it's looking
pretty good.

[David] From taking a picture
of that old Bronco

and all the rust on it
and the condition it was in,

to see it the way it is today,

it's just totally
unbelievable.

You know, last time I seen it
was still all the parts.

-[Kevin] Right.
-We just got it back
from metal,

and everything was just laying
all over the floor.

Yeah, we had a lot of holes
in it.

Most of the rust that we found
was in

-this cowl-like firewall area.
-[David] Yeah.

[Kevin] You can kind of see
we've got all that replaced.

You know, we tried to leave
as much stock metal as we can.

It's thicker,
and I think the metal

was better back then.

Oh, yeah.

[Kevin] So all this is
cleaned up, and then
we got new rockers,

whole new door jams,
toe boards, all the way up

into the firewall.

We went ahead
and put quarters on it,

because these always, like,
trap rust in

-all these layers up in here.
-Oh, okay, yeah.

[Kevin] With this Bronco,
we want to make sure
that if Dave

wants to go off-roading,
into the backcountry,

take it to his cabin,
we want to make sure

it's as safe as it can be.

New roll cage is in,
and I really, really,

really like this roll cage
a lot because it doesn't have

this bar that
comes down here.

Right, right.
Yeah, I didn't want that.

-[Kevin] It's so cluttered.
-[David] You know, always when
I was a kid,

I used to hit my stinking leg
on that all the time.

Right, right.

And we're not kids anymore.

You might still be.

-Well, I mean, okay,
I'll take that.
-[laughs]

We have shoulder belts
on all four corners for seats.

You'll have an actual
shoulder belt versus

only a lap belt,
which will be great.

The car's got a long way
to go,

but they're making some
really good progress.

We did a roof skin.

We found some rust
around the edges,
and it was way easier

-just to dig it all out now
and take care of it.
-[David] Yeah.

The chassis fit very well
into this thing.

And the battery is underneath
the truck now.

-Can you get to them?
-It's lifted.

Dave can almost walk under
here without bending over.

-Oh, really?
-I'm a little taller, so that
just doesn't work for me.

If you don't want to be made
fun of, just be here.

The tailgate is original.

[David] That turned out
pretty nice.

[Kevin] Yeah, looks
really good.

-Actually, our flares that
we make...
-Oh, okay.

[Kevin] Nobody sells a flare
that's this wide

that doesn't have all
of the screws.

[David] Oh, yeah.

And that's the reason
that we--

That's what it had
on it before.

Yeah, that's the reason
we made it.

We wanted kind of
a smoother look.

We put a set of
our door handles in it,

which is really great.

They work 60% of the time,
all the time.

[David laughs]

But let's check out under
the hood, because

-I really think that's where
a lot of the cool thing is.
-Yeah, let's check it out.

Original hood still.

Original hood, which is great.
No more hood prop.

-[David] Oh, great.
-[Kevin] We did it on rams.

So we've already went ahead
and made this stronger

so it doesn't bend,
because these hoods were

never designed to have rams
like that on them.

So when you start
to pull them down,

the hood actually
bends in half.

[David] Well,
this engine is huge.

It's going to fill it up
and really look like

I'm going to like
where it's going.

Master cylinders are in.
Condenser's in.

We got upper and lower
radiator hoses in.

[David] What are you
going to do
on these covers?

-I mean...
-[Kevin] They make
a plastic cover,

but that's not really
the Kindig-It way.

-It's not the Kindig-It way?
-[both laughing]

Well, you know, Dave's kind
of hard to talk to sometimes.

So, you know, you can always
get things done through Kevin.

We don't want to make it
too showy.

We want you to be able
to drive this

and not worry about it.

Just knocking the studs off
of this,

and we're going to paint this.

I'm sure Dave will come up
with a color,

-if he ever shows up today.
-Oh, he's not coming?

Oh, yeah. Oh, that's good.
I felt that one.

There it is.
Look at that.

Yes, sir.

[man] That was nice.

-Yeah.
-I flew all the way up here.

And he's not going
to come.

-Super disapp--
-What, did he have
something come up,

like a hair appointment
or something?

-A little beard appointment.
-Yeah, exactly.

Whether it's a broken leg
or a golf tournament,

Dave just has a lot of [bleep]
going on these days.

So, I mean, so all in all,
everything is going smoothly.

Over the years, I've worn
a lot of hats around here.

I think I could probably wear
Dave's for a day.

How do you feel about
the progress so far?

Well, I like the progress
so far.

I mean, it's getting together,
you know, pretty well.

Time to talk future
design cues.

This is what he was thinking
for the insert.

Kind of like an understated
plaid, and I can see

where he's going with it.
It is a darker color.

Well, I guess, you know,
what I was really not sure on

is this doesn't look
like this.

So, I get what it's like
to be Dave a little bit.

So should I, A,
sell him on this,

or should I, B, just agree?

-Yeah.
-So the renderings

of what he's been showing me
here is this here is more like

-white with, you know...
-Right.

...a little bit of speck
of black.

-[Kevin] Right.
This is a lot darker.
-And you...

You can't really even see,
you know, the grays.

And this here is...

-makes it look a lot better.
-[Kevin] Yeah, I agree.

This is a really good color.

But I still think, I still got
to think about this.

Okay.

I think I've done
the best I can.

It's time to let Dave take it
from here.

-I like it. All right.
-All right, buddy.

-Well, pleasure.
-Appreciate it.

Thank you so much
for coming by.

I will let Dave know
that he missed you.

Yeah, you let him know,
since I've only had it

-set up for three months.
-Right, right.