Check back for weekly updates on the Boosted Bronco build. Learn about Aaron Vaccar and the build partners.

Back to Boosted Bronco

October 27, 2017

Ready for sandblasting

Before we can even think about applying the WD-40 themed color change and custom bodywork, the entire vehicle must be media blasted to reveal the true condition of this '66 survivor.

Keeping Boosted Bronco's simple dashboard

There's a certain allure of leaving select period-correct details on the Bronco build – the dashboard, for example, will still boast retro relics as a part of the finished product.

Sandblasting in progress

Scenic shot of key Ford Bronco details hiding in the dust of the high-pressure sandblasting.

Preparing the metal surfaces down the smallest detail

Preparing the body and metal of the Bronco will require careful processes as to assure it's done right the first time, giving special attention to the areas requiring more work.

Farewell to the 1966 drivetrain

As the sun sets outside the Vaccar shop, the team is beaming brightly to see the fully assembled 2017 Ford drivetrain lower into it's new home in the 1966 Bronco engine bay.

The Bronco's new custom transfer case

With the Bronco's four-wheel-drive system as a staple feature to remain true in the end product, a custom transfer case adapter was crafted to allow a 'bolt-on' application of the new EcoBoost motor and modern transmission.

Vaccar technician applies first coat of paint

You never quite know what foundation you're working with on a restoration job, until you strip years of previous, sometimes multiple, paint work.

Bronco is sandblasted and ready for repair

Here, the Bronco is at an almost entirely 'bare' state of being, which means we're ready to repair and replace damaged original body parts that likely date back to 1966.

Adding some style with a custom steering wheel

A limited WD-40 x Vaccar collaboration steering wheel was crafted to place final touches on what is a 'one of one' custom vehicle build.

WD-40 Specialist Rust Release Penetrant Spray breaks down rust build up

Handling and gears is less of a mess when lubricated using WD-40® Specialist® Spray & Stay Gel Lubricant.

The Bronco's new V6 motor

Hello EcoBoost! While the Bronco's new engine appears to be a tight fit, it does fill up the engine bay in a visually pleasing way.

Adding an auxiliary performance gauge

The additional of auxiliary performance gauges will help monitor engine vitals, as well as create a more engaging driving experience.

Fabrication of custom motor mounts requires careful measurements

Before the Vaccar team can fabricate custom mounts for the motor, they'll need to measure for clearance and proper level.

The Bronco's new custom transfer case

A special adapter was utilized to maintain the Bronco's original 4WD transfer case with the modern engine and transmission.

WD-40 Specialist Rust Release Penetrant Spray breaks down rust build up

Aaron Vaccar keeps his tools in top condition. He prefers WD-40 Specialist Protective White Lithium Grease for moving, metal-on-metal applications.

WD-40 Specialist Rust Release Penetrant Spray breaks down rust build up

Some of the WD-40/SEMA Cares Boosted Bronco's electronic connections were worth saving, but they needed safely cleaned with WD-40 Specialist Electrical Contact Cleaner Spray before reusing to get rid of dirt and other residue.

October 5, 2017

Clean out the clutter

Before the Vaccar team can properly assess the situation, we need to clear out the clutter from the Bronco’s interior.

Boosted Bronco stores extra motor

There were so many parts being stored inside the Bronco, that we literally found an extra motor! This Bronco engine bay is equipped with an original inline-6 motor - and apparently someone had plans for a V-8 swap – but, our plans include a Ford Performance EcoBoost, twin-turbo V-6!

Bare Boosted Bronco

With the interior now down to the bare floor, the team will work from the bottom up, making notes of 'what' and 'where' there are signs of rust or other signs of age that will need addressed in the process of this resto-mod.

Keeping Boosted Bronco's simple dashboard'

The dashboard is simplicity at its finest – and there's nothing bad about that. In fact, we intend to keep that theme while restoring the trim and adding detailed bits of customizations. Bronco aficionados might spot out the unique characteristic of this '66 model and its options from the factory.

Under the hood of the Boosted Bronco

Open wide! This is the moment we've been waiting for. Although we’ve known from the beginning that the Bronco’s engine will be swapped, it’s still equally exciting to turn back in time and take a look at its original motor.

The Bronco's old six-cylinder motor

This Bronco was an original straight six-cylinder motor, and it's strangely fitting to be going with a six cylinder again – however, it will be a “V” formation, and with turbos hanging off each side!

Farewell to the 1966 drivetrain

It almost seems like the Bronco is saying “farewell” to its 1966 drivetrain. In fact, shown here is its engine, transmission, and transfer case all being removed at once. However, we think it'll be happy with its new trifecta of horsepower.

WD-40 Specialist Rust Release Penetrant Spray breaks down rust build up

Before we lay one wrench in this ancient engine bay, our team will reach for a can of WD-40® Specialist® Rust Release Penetrant Spray. Why? Because aggressive rust that took years to build up will be broken down within minutes. It saves the team time (and frustration), and that is a valuable project-build asset.

Tell your friends!