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  #313  
Old 05-26-2012, 08:22 AM
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Re: Grand Willys project

Omg this is such an amazing build. I am always amazed at how brilliant you are and how you always seem to have every detail covered! I can't wait to see this thing come alive! The rolling chassis will look so cool.
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  #314  
Old 05-26-2012, 09:58 AM
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Re: Grand Willys project

We do because we can!!!
Outstanding attention to detail at every stage.
In for the longhall. All the best from the UK.
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  #315  
Old 05-27-2012, 03:18 AM
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Re: Grand Willys project

Thanks for the interest in the build guys.
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  #316  
Old 05-27-2012, 03:23 AM
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Re: Grand Willys project

I think AWE would be closed to the mark!

So when do you think you could go into production? might even be better than a brute!


Dave
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  #317  
Old 05-29-2012, 03:34 AM
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Re: Grand Willys project

Even Jeep is into the 'what is old is new again' theme at the moment. I like what they did with this one.
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  #318  
Old 05-30-2012, 05:49 AM
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Re: Grand Willys project


Mount sits flush against the rail now.


I found that one of the rails was nearly 3mm-1/8" lower than the other side at the end of the rail. As I don't have an oxy, I just ran an extra weld bead on the inside of the bend and then cooled the weld with the air gun to help it shrink. This caused the bend to tighten and lift the end of the rail level with the other one.


With the rails were perfectly level to each other, I could then level the two mounts against each other. I went off the upper wishbone mounting holes on both sides as their angles and height are the most important.


Welded in.




Started on making the templates for the boxing plate. To make the swaybar bush hole I just hit the top of it until it broke through.


Trimmed the outsides with a utility knife. I used craft paper or card stock. Just bought A4 packs of 10 for $2.50 from the $2 shop and taped them together.


Hoping I can make the whole boxing plate in only two sections.
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  #319  
Old 06-02-2012, 06:55 AM
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Re: Grand Willys project


First time with new steel used on the project. Starting with a fresh sheet of 2440x1220x4mm or 8'x4'x5/32"


First one done. You can just make out the slots where the supports for the welded in mounts will come through it.


Last one getting done with about half the sheet used plus some left overs which will be used for mounting brackets etc.


I just made the pattern for one side and will just flip half of them for the other side. Glad I took the time to make them as identical as possible.


Was surprised just how well it fitted first go! Wasn't sure how accurate my CAD, Cardboard Aided Design, would work on this. You can also see the other side plate, which is upside down, that it has be coated in weld through zinc rich primer to help against rusting inside the rails.


The templates were narrowed each side by the thickness of the flange, leaving a nice corner the fully weld closed. Fit well over the swaybar boss that had already been fully welded in. The other hole is for the rear shock mount bush that was drilled at a 8* angle the same as stock. I drilled these before putting them on the rails so no swarf would end up inside the rails.


The front half is going to be a lot harder as not perfectly flat like the rear. A total of 6 bends will have to be pressed in to follow the bends in the rail and the flange width changes.
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  #320  
Old 06-09-2012, 08:09 AM
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Re: Grand Willys project


To make the needed bends in the boxing plate to follow the frame shape, I just used a blunted brickies bolster and hit it between two sections of steel. Can use a piece of channel too.


The bends are following the frame shape quite well.


Can see in this shot how the edge of the cross member mount comes through the boxing plate where it will be welded and then ground smooth.
Also shows the only joint in the whole boxing plate. This shape increases the weld area and has the least amount of stress rises.


All plated up. Also seen is the front cradle mounts coming though and flush with the boxing plate, ready to be welded and then ground smooth.


This is part of the Grand Cherokee frame that has the rear shock mount in it. I was fortunate that the narrow section it sits in was similar to the width of the Willys frame. When I laid out the width of the Willys frame, I made sure it would run exactly along where this mount needed to be.


This is the hole for the shock mount in the Willys frame drilled at an 8* angle to match how it was in the Grand Cherokee.


Original shock mount was cut free with a hole saw and then welded in to the frame on both sides. Another piece of metal will be formed to support the other side of the shock eye so it will be in a double shear arrangement like the original setup.


Also finished welding in the other end of the swaybar mount.
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  #321  
Old 06-09-2012, 09:39 AM
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Re: Grand Willys project

I am so enjoying my weekly intake. Thanks....
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  #322  
Old 06-10-2012, 03:41 AM
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Re: Grand Willys project

Quote:
Originally Posted by UKWK View Post
I am so enjoying my weekly intake. Thanks....
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  #323  
Old 06-10-2012, 06:11 AM
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Re: Grand Willys project

Just had to say a big thank you for the tip of using the copper to plug holes. Had to do that yesterday and flattened a bit of 1 1/2 water pipe and plugged the hole a treat....
Just got to get my upside down welds looking as good as the right side up ones now.....
Thanks again...
Alex
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  #324  
Old 06-11-2012, 04:52 AM
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Re: Grand Willys project

Glad it worked well for you. Upside down and over head are the hardest to do for sure.
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