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  #301  
Old 05-02-2012, 08:47 PM
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Re: Grand Willys project


Time to start on my first cross member. I must have at least two originals for it to be registered as a 48 Willys under club registration rules, in case I go that way for a 90 days a year permit. For full road registration I still require at least one.


Looking a bit worse for wear with rust, twists, bends, dents, holes and buckles!


The old PTO hole was a bit big to just fill with weld so dropped in a washer of the same thickness as the frame.


The copper spoon also works well on edges that need to be repaired.


A lot faster and less heat this way.


Well 40 odd holes filled and a lot of tacks on some rust pitting that was first cleaned out with my die grinder.


Both ends were twisted 5 degrees in the same direction. Most likely the centre section, where the tow hitch was welded on, was bent up after dropping onto a rock ledge.


Just bolted on the old rear cross member from the other frame to lever down on the ends while the press holds the centre steady.


All the twist gone.


As you can see the ends taper up to the same height as the end of the frame rails. Problem is that I am running the rear of the frame 6.5" narrower to match the width of the frame under the Grand Cherokee and all the axle bracket positions. These trucks have a 6.5" wider rear axle than the front and I will be running the same width front and rear.


After cutting to the new length, the ends no longer match the ends of the frame rails. So a wedge was cut out and the flange bent up to match it.


I will box this member as will be used to support a towbar as well.
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  #302  
Old 05-02-2012, 09:31 PM
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Amazing work Gojeep. Keep it up!
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  #303  
Old 05-09-2012, 08:23 AM
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Re: Grand Willys project

Looking real good!!
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  #304  
Old 05-10-2012, 03:39 AM
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Re: Grand Willys project

Thanks mate. Getting held up at the moment as can't get a measurement I need so I know where to weld in the mounting nuts inside the frame rail for the fuel tank before I box the frame rails. Just need to know from the centre of the cross member to the first bolt holding the skid on under the frame rail.
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  #305  
Old 05-11-2012, 03:39 AM
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Re: Grand Willys project

A big thanks go to Dr. Lee on here for getting the measurement I needed.
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  #306  
Old 05-12-2012, 07:35 PM
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Re: Grand Willys project

Wait wait wait,
are you one of these guys!??

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  #307  
Old 05-13-2012, 04:14 AM
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Re: Grand Willys project

Ha ha, no I am not but done the same tracks though towing my offroad camper which is a lot lighter and smaller than what they do!
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  #308  
Old 05-14-2012, 11:52 PM
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Re: Grand Willys project

ah well thats badass anyway !
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  #309  
Old 05-19-2012, 06:19 AM
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Re: Grand Willys project

First parts of the donor Grand Cherokee are getting used!
Getting everything ready that must be done before boxing the frame rails start.


This is the engine and lower front suspension cradle sitting under the frame rail for the first time to check angles. The area where it bolts in the front was 3 degrees out. The lower flange of the rail needed to be titled down at the back to sit flat on top of the cradle.


Rather than cut and bend the flange down, I bolted in a piece of heavy angle iron the same size as the area it sits on the cradle. Then supported the back end of the frame rail and then simply stood on the end of the cradle pushing it down. This bent the lower flange down giving a nice smooth transition.


I have cut out the original mounts from the Grand Cherokee so that every thing is mounted in the exact same manner as the engineers designed it. This is the mount for the front of the engine cradle.


The threaded boss has some movement to allow fine adjustment when it bolts together. The supporting plate has been cut wider than the flanges so it will protrude through a slot cut into the boxing plate when it goes over it. It will then fully welded and ground smooth. This way it is supported on both sides like it was originally.


These are the mounts for the transmission and transfercase cross member welded in. Interesting how the engineers have the actual attachment point higher up in the frame rail rather than directly on the bottom flange. I would think this would add greater torsional rigidity, so why not utilize it


The threaded nut plate has been clicked into place and the support plate again had been made wider than the flange by the thickness of the boxing plate. It will have a slot cut in it so the support plate can be welded to it.


Also cut out of the frame of the Grand Cherokee the mounts for the rear panhard rod, or track bar, which bolts into the frame. I left part of the original frame attached to the threaded boss and welded around the perimeter. The other two large holes you can see are for the shock absorber and sway bar mounts.


You can also see here extra threaded bosses welded in case I am able to mount the fuel tank in the same position as it was in the Grand Cherokee under the cab floor next to the driveshaft. Many thanks to Dr. Lee of South Dakota for getting under his Grand Cherokee and getting the measurement I needed for that. Hadn't recorded it initially as didn't think it would be possible, but now think there is a chance and better to have them in place as cant add them later once it all is boxed


These are the mounts for the rear sway bar. They pass right through the frame rail and will be supported on the other side as well once the boxing is complete.


Sway bar mount ready to have the boxing plate laid over it and then fully welded.
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  #310  
Old 05-19-2012, 05:13 PM
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Re: Grand Willys project

Wow I love that you post all of this amazingly detailed work! Thank you and i will be in this thread for the duration
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  #311  
Old 05-20-2012, 04:28 AM
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Re: Grand Willys project

Quote:
Originally Posted by 08Hemi View Post
Wow I love that you post all of this amazingly detailed work! Thank you and i will be in this thread for the duration
Good to hear. Helps me remember where all the time went as well!
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  #312  
Old 05-26-2012, 07:14 AM
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Re: Grand Willys project


You might remember how the stock frame looked before I started altering the bends nearly 12 months ago.


I ended up only moving the rear most bend on the original configuration forward so that the rails will run parallel now starting at the firewall rather than the the forward mounts of the rear leaf springs part way down under the bed.


This is the biggest part that will be added to the frame rails from the Grand Cherokee. This is the support bracket for the upper wishbone and the coilover. Technically the upper wishbone on these is what makes it a coilover rather than a strut. A strut also plays a roll in locating the hub where as a coilover does not, but often the term now a days is used for both.


The pressing here is for extra lateral strength and to clear the coilover. It needs to be recessed into the rail to centre the load more above the rail and reduce twisting leverage. When I made the new bends in the frame I took this into account.


I find it easier to weld the plate that will line the notch on the frame rail over the actual mount so all the angles are correct.


I first clamped the mount back into place on the rail and then clamped the new plate section to the back of it inside the rail so I knew everything was in the right position. Then tacked from the inside before removing the mount so it could be welded. You can also see compared to the rail in the background, how I have extended the wider section of the flange past the notched section. I have added as much as the notch is deep so no lateral strength has been lost.


Starting to fully weld the plate in.


It was also fully welded from the back.


The section that will end up behind the mount has been coated with weld through primer to protect against rust between the two layers.


All angles and the position is double checked against what I recorded before pulling apart the Grand Cherokee. I have even have it over the same bit of concrete to keep things as accurate as possible having recorded the measurements on both paper and photos.
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