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  #385  
Old 10-13-2012, 04:55 AM
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Re: Grand Willys project


This is the pedestal that the caged nut sits on from inside the donor frame. It will be welded inside the new mount so the original arrangement is used.


Welded the mount into place.


I also curved the top piece so it looked more factory and also gave me a bit more clearance above the caged nut so the bolt had plenty of threads showing through it.


This gives you a better idea of how it is braced across the bottom of the frame rail for support.


With the bracing done underneath the frame instead of up the side of it, I have left room in case I make my headers come over the mount.


That completes the mounting of the cradle. Might not look like it but that now means I have the mounts for the front swaybar, steering rack, front differential, engine mounts, upper and lower wishbones and the upper and lower coil/strut mounts finished. Time to move onto the rear.
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  #386  
Old 10-14-2012, 05:55 AM
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Re: Grand Willys project


A big piece from the donor going in now.
One Chrysler rear axle with a 8.3" ring gear, electronic limited slip diff with a 3.73:1 ratio. 12.6" discs with ABS.


Centred the axle under the coil mounts by placing a level vertically each side of the axle housing and measuring back to the centre of the coil hat. Can only do this if you were careful with the placement of those in the first place of coarse.


The panhard rod bolted right in and placed the axle within a millimetre of dead centre, which surprised me actually. My XJ Jeep was about 10 mm out while still stock from new.


Now for the lower control arm mounts. After carefully removing the stock one a while ago, was not able to use it. This frame starts kicking up much earlier at a shallower angle than the donor, so misses by a lot.


With the axle sitting at the exact height in relationship to the other suspension points already mounted to the frame, I could set the arm angles up the same as factory. This will give me the correct roll centre, anti dive etc as the Jeep engineers worked out in relation to the front end arrangement.


When I laid out the frame rail spacing, I also took into account that the inner frame rail would line up with the inside of the lower control arm bush. I will just have to step out the outside of the mount to line up.


Just did a rough layout using taped pieces of recycled A4 paper. I left a 10mm-3/8" extra around the control arm end. I'd rather that if it ever hits something, that the bracket takes the weight rather than the arm and bush.


The outside angles of the bracket is set at 22.5*. Very common angle used in engineering and even my house roof is at this pitch. It also worked out that it would cover the upper control arm mount as well. The extra V taken out of the top is for a few reasons. One is that it then makes the weld length on the top and bottom of the rail the same. The top would have been 50% longer otherwise if fully welded and that would have caused the frame to bend upwards after welding. It also allows welds in the middle of the bracket increasing its strength. Lastly it reduces the weight of the bracket both physically and visually. Can also see the fold I will be putting in to accept the extra width the bush has over the frame width.


Time to start cutting out the new brackets from some of the left over 4mm plate I bought for boxing the rails. There is a inner and outer template due to needing extra length for the fold that goes into the outer one. The curved bit at the bottom of the V was first cut out using a hole saw. Then the rest just using a 9" cutoff wheel.


Now the lower arms do not run exactly parallel with the frame and skew outwards by 3*. This is common and helps reduce binding during axle articulation. The way they set the original mounts up was to press the 3* around the mounting hole.


I decided to do simulate the factory way by cutting out a 2" disc using a hole saw around the mounting point, tacking it in top and bottom, then tilting it to 3*.


Then fully welding it back in again. It is not much of a tilt, but means the bush wont be under constant tension if it had not been done and will therefore last a lot longer.
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  #387  
Old 10-15-2012, 09:54 AM
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Re: Grand Willys project

pure awesomeness again. cant wait for more.
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  #388  
Old 10-16-2012, 05:27 PM
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Re: Grand Willys project

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Originally Posted by Antonio186 View Post
pure awesomeness again. cant wait for more.

X2, now we can really see her coming together. Awesome work, keep er coming!
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  #389  
Old 10-17-2012, 02:38 AM
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Re: Grand Willys project

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Originally Posted by soontobesrt View Post
X2, now we can really see her coming together. Awesome work, keep er coming!
More relevant stuff to this forum now going in with some more WK bits going into it
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  #390  
Old 10-17-2012, 08:35 AM
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Re: Grand Willys project

Hell of a project! Can not wait to see the final result
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  #391  
Old 10-17-2012, 04:41 PM
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Re: Grand Willys project

Looks to be a great ride when finished!
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  #392  
Old 10-21-2012, 05:03 AM
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Re: Grand Willys project


Fold has been put in the outside plate. Did the first one cold with just a hammer in the vice, but found it easier to preheat it with a propane torch to do the others.


This is how the original upper control arm mounted. The donor frame kicked inwards a bit at this point and the sides of the frame were not vertical. That is why the gap on the inside of the bracket.


The control arm actually sits on the end of the tube that passed right through the frame to the outside. I want to do the same thing but will use the lower control arm brackets as my frame kicks up too high.


I have cut away the tubing from the bracket as don't need the peice of sheet metal it was attached too. My control arm bracket is twice the thickness of the frame rail that it was originally spot welded too and will weld it directly to it. I left the extra to see if I can bend it out to fill the gap between the bracket and the frame rail.


The fold now has been straightened out just using the two hammers shown and the anvil. Just requires some dressing yet.


The UCA's, (Upper Control Arms) angle inwards at 10 degrees. I made sure the bracket matched the angle and was level the other way.


Here are the upper and lower control arm brackets mocked are into place to check that all lines up before the welding is done. It is crucial that the pinion angle is properly set also. This one is at 6* as it was from the factory and it matches exactly the output flange of the transfercase. Cars are usually around 3* with their drive-line angle with there gear box and pinion angle matching to prevent vibes.


Main plates welded in.
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  #393  
Old 10-21-2012, 08:18 AM
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Re: Grand Willys project

Excited to see your latest update. Much better than the Sunday paper! I continue to be astounded by your knowledge and skill. Thanks for keeping us all current with your progrees.
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  #394  
Old 10-21-2012, 08:21 AM
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Re: Grand Willys project

Fantastic update! I love to see this project come alive!! Keep the updates coming! I look forward to the weekly build updates!!
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  #395  
Old 10-22-2012, 10:59 PM
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Re: Grand Willys project

Anyone that has only joined this thread since the start of September would have missed out on all the photos at the start of the build. I had the pictures hosted on Facebook but they changed all the thread links when they went to the new large thumbnail format. So have spent the last couple of days re-linking over 400 photos so any new followers can see the progression.

Cheers
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  #396  
Old 10-22-2012, 11:17 PM
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Re: Grand Willys project

really enjoyed looking through this build!
gave me something to do at work for a couple hours ha

Very impressive!
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