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  #265  
Old 02-28-2012, 02:58 AM
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Re: Grand Willys project

Simply amazing...I'm in this thread for the long haul. Very excited to see the two mate!!
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  #266  
Old 02-28-2012, 03:05 AM
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Re: Grand Willys project

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Originally Posted by 08Hemi View Post
Simply amazing...I'm in this thread for the long haul. Very excited to see the two mate!!
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  #267  
Old 02-28-2012, 05:42 AM
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Re: Grand Willys project


This is my starting height where the rail sits over the rear axle centreline. Looking at gaining 100mm or 4" to match the height it was stock on the Grand Cherokee.


The first bend will be where the rust was cut away. So the flat section on the floor is what goes under the cab before kicking up over the axle.


Decided to just press the first bend seeing I already had so much cut away. Calculated I needed a 7.5* increase. Can already see the change in height. Now have to bend the rear section so it is parallel once again with the ground.


So cut out a 7.5* wedge out of the frame.


Worked out rather well


Showing penetration on the back side of the weld. The round bit off the the side was the old hole in the rail.


Left welding the flange as had rusted out above where the bump stop was.


Cut the section out and made it a little longer to remove some of the holes at the same time.


Cut a piece to fit and hammered in a matching curve. Brought back memories of my Blacksmith/Farriering days of my youth.


Getting used to the welder. First pass on the right was too hot so turned it down a touch for the other two passes.
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  #268  
Old 02-28-2012, 09:14 AM
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Re: Grand Willys project

Gojeep, it would be nice if you added a modern touch to this when it's done by putting on some aftermarkets wheels. 20" in the front and 22" in the rear.

What color do you want it to be? I'd say do a military green with black wheels.
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  #269  
Old 02-29-2012, 03:16 AM
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Re: Grand Willys project

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Originally Posted by lll2for3lll View Post
Gojeep, it would be nice if you added a modern touch to this when it's done by putting on some aftermarkets wheels. 20" in the front and 22" in the rear.

What color do you want it to be? I'd say do a military green with black wheels.
Not the look I am going for at this stage. Want it to be a bit of a sleeper but with a stand out paint job. Stockish looking outside and modern underneath and inside.

Paint colour at the moment is the 2012 Wrangler colour.
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  #270  
Old 02-29-2012, 03:19 AM
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Re: Grand Willys project


This gives a good representation of the changes I just made to the first rail placed behind the stock one.


Both done.
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  #271  
Old 02-29-2012, 07:15 AM
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Re: Grand Willys project

Would you still be willing to paint the stock wheels black with that Wrangler Orange? Black wheels would look very nice.
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  #272  
Old 02-29-2012, 07:39 AM
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Re: Grand Willys project

Quote:
Originally Posted by Gojeep View Post
Not the look I am going for at this stage. Want it to be a bit of a sleeper but with a stand out paint job. Stockish looking outside and modern underneath and inside.

Paint colour at the moment is the 2012 Wrangler colour.
I like your tentative choice of color. I like the way classic vehicles pop with modern colors.
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  #273  
Old 02-29-2012, 08:17 AM
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Re: Grand Willys project

8 years ago a friend bought a Cobra kit car and was going to paint it Inferno Red (which at the time I thought was a great choice). He never completed the car, but if he had completed it in Inferno Red, I think the paint would look a little dated now because it had been used on so many vehicles in the 2000s. I love the 2012 Wrangler orange today, but for a retro-vehicle that you're probably going to keep for a long time, I'd personally choose an updated version (maybe add metal flake) of a color that might have originally been on the Willys. You'd probably have a better chance of enjoying the color today and tomorrow.
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  #274  
Old 02-29-2012, 09:43 AM
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Re: Grand Willys project

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Originally Posted by RedRocker View Post
8 years ago a friend bought a Cobra kit car and was going to paint it Inferno Red (which at the time I thought was a great choice). He never completed the car, but if he had completed it in Inferno Red, I think the paint would look a little dated now because it had been used on so many vehicles in the 2000s. I love the 2012 Wrangler orange today, but for a retro-vehicle that you're probably going to keep for a long time, I'd personally choose an updated version (maybe add metal flake) of a color that might have originally been on the Willys. You'd probably have a better chance of enjoying the color today and tomorrow.
aggree'd but what ever color is chosen this is an incredible build project
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  #275  
Old 03-07-2012, 06:56 PM
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Re: Grand Willys project


Stock rail from the 58 frame on the right verses the modified 48 on the left.


Shows how much changed when this bend was pressed in for the bigger kick over the rear axle.


Time to make a template to replace the rusted out section. Made sure the straight lines from each side continued on.


A curve was added using the old piece taken out as a guide.


Dragged out my old anvil from when I was a Blacksmith/Farrier. This is the small 125lb one that I kept it the back of my truck when shoeing horses to alter the shoes to fit. I have hammered the new flange to match the curve of the rust repair piece.


Checking the flange to make sure it follows the rail correctly.


Patch piece tacked in. It wont be welded in fully until the fish plate behind this bend is installed. That way the bend wont alter and the weld penetration will go into the fish plate along the join as well making it stronger.


Just laying out the fish plate on the opposite side to which it will be installed. This is the way I do them using the Government Street Rod Manual as I guide and what I was taught working in the structural steel industry. Only thing changed is the radius on the ends to remove a possible stress riser there.
It needs to be of the same material thickness as the parent metal of the rail, 4x longer than the height of the rail over all. Half of it will be without taper with the remaining 25% each side tapering off to a radius 25% of the height of the rail. So in this case the rail is 4" high so 16" long with the taper on each side 4" long to a 1" radius. I just use a socket to draw around. The reason for the taper is so that there is a gradual increase/decrease in stiffness in and out of the bend. This stops stress risers from occurring. Same reason for rounding the ends as well, a point would cause a high stress concentration.


Using the frame rail from the 58 chassis to make my fish plates. The holes are a bonus as will use them to plug weld into the back of the rail.


Rail looking pretty sad now.
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  #276  
Old 03-10-2012, 05:55 AM
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Re: Grand Willys project


Area behind the fish plates and the back of the fish plates themselves was cleaned of any rust and paint. Small spots left were also blasted with garnet before plates and rail was hit with weld through zinc rich coating to give some protection between the layers. Often called a primer but that is not the case of most as you cannot paint over it with something else, so only use on the back of panels etc that wont see a top coat. Not all done yet in this photo.


Plates welded in.


Repair patch looking better too. Showing some marks from where had to hammer and dolly the now 3/8"-10mm thick section to flatten the seam where the weld for the patch was. Might be getting a bit carried away hammer finishing a chassis!
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