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  #157  
Old 05-30-2011, 03:58 AM
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Re: Grand Willys project

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Originally Posted by 555ctsv View Post
Great setup you got there man! I love all these pics. Looks like your moving forward quite well
Thanks mate and glad you like all the pictures. I worry I put up too many at times and have many more that I don't show.
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  #158  
Old 05-30-2011, 11:24 AM
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Re: Grand Willys project

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Originally Posted by Gojeep View Post
I worry I put up too many at times and have many more that I don't show.
I enjoy reading your updates! keep posting pics etc. I would've thought that you would test fit the WK chassis on your Willys frame, but it sounds like you are tearing the frame a part.
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  #159  
Old 05-31-2011, 09:31 PM
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Re: Grand Willys project

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Originally Posted by Gojeep View Post

Woo hoo, time to lift off the cab. Rolled the chassis and cab under my carport in front of the workshop where I still have this winch setup. It is a boat trailer winch that is though bolted to the centre carport post. The cable then runs over a pipe that it bolted between two rafters. The lifting frame was when many years ago I had a roof top tent that I made this setup for so I could simply park under it and remove or install it by myself. Just left the camper pack sitting up in the air the rest of the time.


We have lift off. Was very easy and fuss free and my wife even did all the winching by herself.


Back down on a old shopping trolley base ready to go for a ride.


Got some strange looks as we had to go up the footpath.


And around the corner to the front of the house.


Will sit in the garage where the camper trailer normally lives until I am ready to work on it.


Chassis is now ready for the big strip down. Heard it can be quite hard removing all the frame rivets and there are plenty of those holding every bracket and cross member in. Hoping grinding the head off and then using an air chisel with a punch bit will work. Got some rose welds to try and remove as well without damaging the cross member inside the rail.



Awesome man! Love the hose reel as well, very creative use of a busted wheel haha!

And the airchisel and punch will certainly rid those old rivets from the chassis. I thought it was funny that the doors were held on simply by some old Phillips heads haha, shows how far we have come. I believe they would hold it for somme time (as it has) but as you said, if one of those stripped somehow, Can only imagine the havoc that could cause down the highway. Id definitely look into a better hinge setup for those doors, but thats a ways off I bet. Cant wait to see some Jeep suspension under that Willys
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  #160  
Old 06-01-2011, 12:26 PM
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Re: Grand Willys project

man i cant wait till this thing is done... how far along would you say you were in the project? like 25% ??
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  #161  
Old 06-01-2011, 08:06 PM
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Re: Grand Willys project

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Originally Posted by DGora31 View Post
man i cant wait till this thing is done... how far along would you say you were in the project? like 25% ??
No where near that much. I don't even count this so far as have not starting even building yet!
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  #162  
Old 06-01-2011, 08:15 PM
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Re: Grand Willys project


Had a bit if think of the best way to remove these big rosette or plug welds which hold the front cross member in. I didn't want a big hole left in the front cross member after wards as well as might be reusing it.


So thought I would use the same drill bit I ground up to take out the spot welds, as it drills flat rather than a chamfered hole, and stop before going into the cross member. You can see one done now and the next one ready with the pilot holes drilled.


Didn't need to drill the center hole in the end so didn't drill that when doing the other side. It easily broke free when I drove a cold chisel in a bit.


What a MESS! Who would think a frame could hold so much dirt. Seeing this Willys came off a potato farm until it was sold off when he was done for cultivating drugs, it is not surprising! Maybe I should keep the soil and water it to see what come up!
There is just so much more to remove than just the cross members to get down the bare rails.


This angle gives you a bit of idea how much kick up the frame has at each end. I will be increasing that by another 2" front and 4" rear.
Now I must be off to clean the workshop
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  #163  
Old 06-01-2011, 08:54 PM
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Re: Grand Willys project

Superb update mate!

You seem to have given away the Aussie hose reel though

The amount of measuring you must do makes my eyes boggle
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  #164  
Old 06-02-2011, 03:29 AM
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Re: Grand Willys project

Thanks mate, just hope I measured enough!
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  #165  
Old 06-04-2011, 06:52 AM
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Re: Grand Willys project


Rails have come up much better than expected after several hours of grinding and wire brushing them clean. Only thing is I counted a 111 rivet holes that will all be needed to be welded up in each rail.


This gives you an idea of the frame bends horizontally before I start modifying it to suit the suspension pickup points of the donor Grands rear and its front sub frame.


Rear height where the coil mount will sit. Will increase this by 100mm/4"


This is the starting height at the front of the frame rail where the front mount of the Grands sub frame will bolt in. Will have to raise this point by bending the front of the rail upwards.


This is the only rust on the whole frame and at the same place on the other rail too. It is where the frame kicks up behind the cab. This happened as some one had added a extra plate to the outside which was only stitched welded on and the gaps let the water and dust in. Rail is bent more than it should be slightly at this point which is fine as will be bending it more anyway.
Thinking of cutting this section out, but leaving the flanges, and adding in a new piece with the extra curve in it that I need, and then bend the flanges to suit it.


Found what looks to be a frame manufactures date too. 9.11.58. Hard to make out the last figure now though as thought I was removing more from the top of it and it disappeared instead.
So parts so far are 50 years apart with the Grand Cherokee donor being made in 2008. Still hoping to pick up another donor made in 1948 for the other half of the frame and body work too if the guy will ever set a reasonable price.
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  #166  
Old 06-08-2011, 08:03 PM
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Re: Grand Willys project


Removed the bent knuckle that took some of the impact from the Harley hitting it. Can see here just how much it bent compared to the new one on the right. Glad really that the cast aluminium knuckle bent rather than the cast steel lower or the forged upper wishbone did. Their mounts were unaffected too.


Both of these are sitting dead flat on the lower ball joint surface. Amazing how much change there is in vertical height as well.


Removed the Hemi, trans and transfercase from the sub frame so I can work on mounting the engine mounts further back in the sub frame so the axle centre line is centred in the wheel arch.


Moving the engine back meant that the oil filter would end up on top of my steering rack. Noticed that it was fitted to an angled adaptor so removed it.


This left this behind but with nothing to screw the filter back on to.


This is the adaptor with the threaded part for the oil filter and the oil pressure gauge sender.


The threaded section just simply unscrewed with an Allen key and installed into the block directly.


The adaptor also had the oil pressure gauge sender so had to find a new place for that. Noticed this plug above the oil temperature sender.


The oil pressure sensor was too big to fit into the upper hole, so swapped the oil temp sensor in there instead. The thread however on the oil pressure sender was too small and I didn't have an adaptor. So I drilled out the plug that was in the upper port originally and threaded it for the sensor and installed it that way
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  #167  
Old 06-09-2011, 08:35 PM
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Re: Grand Willys project


Gives you a better idea of the sub frame that holds everything under the uni-bodied Grand Cherokee. Just held in place with four big bolts. I will be doing the same so I can bolt it under the Willys frame.
Paint damage in the front corner is from the battery acid leaking on to it after battery was split in the impact with a tree after being hit by the Harley.


Just got to workout how I will make my new engine mounts once I move them 175mm back on this frame to centre the axle under the wheel arch. As the frame drops away steeply, cant just weld the old brackets back in place. Also going to end up over the top of the rear diff mount on the far side.
Going to be fun setting it exactly right too as the mounts are 16mm lower on one side and 18 mm further across than the other side. Cant centre it otherwise the front driveshaft would hit the side of the transmission. They also have to have a 5.5 degree tilt to match the stock engine angle.
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  #168  
Old 06-11-2011, 06:14 AM
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Re: Grand Willys project


What's up with the way they routed the hose along the bottom of the cross member? Starts in the middle of the fan when in place, then goes across all the way to one side, then the other side, back part of the way and then over the cross member before entering the steering rack!
I take it is something left over from a LHD to RHD design change? Can't see any other reason for it.


Taken the front diff out. Nice finned alloy cover and axle housing.


Got a nice alloy oil pan on the engine too standard. If you can see it after it is installed, might have to give it a polish!


Here is the sub frame stripped bare.
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