Go Back   Jeep Garage - Jeep Forum > Photo/Video > Members Rides

Join Jeep Garage Today
Reply
 
Thread Tools Display Modes
 
  #565  
Old 05-19-2013, 06:21 PM
bluethunderjeep's Avatar
Premium Member
My Jeep: 2005 5.7L WK
 
Join Date: May 2010
Location: Halifax, Nova Scotia
Posts: 242
Thanks: 5
Thanked 0 Times in 0 Posts
Rep Power: 19293
bluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond reputebluethunderjeep has a reputation beyond repute
Re: Grand Willys project

The Discovery Channel should be making a reality show on this project.
Wow. Just wow.

Dave
__________________

__________________
2005 Midnight Blue 5.7 QDII
Mopar CAI
SRT Pedals
Superchipped 91 tune
Firestone Destination AT's
Infinity Reference speaker upgrade
Reply With Quote
  #566  
Old 05-25-2013, 07:36 AM
Member
 
Join Date: Jul 2010
Location: Australia
Posts: 826
Thanks: 1
Thanked 25 Times in 24 Posts
Rep Power: 1658890
Gojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond repute
Re: Grand Willys project


Time to start a bit of work on the firewall and floor from the 2008 Jeep Grand Cherokee donor. Having pulled out most of the damage from the impact into this corner from the Harley rider hitting it, wanted to see if I could get it any smoother.


This was the extent of the damage originally at the firewall to toe board seam that you might remember. The firewall/floor is upside down so you are looking from the bottom down.


The crease in the toe board.


These are the tools I have recently bought to smooth out the panel. This is all pretty new to me as learnt my welding trade in the structural steel industry. That and blacksmithing doesn't deal with light thin sheet metal. Even when I worked building aerofoil impellers etc, the parts I made were formed in huge presses, so very little hand forming.


Using the slapping file with the dolly behind it, can see how the imprints from the serrations are pushing down the high spots while the dolly brings up the low ones.


You just keep at it until the low spots also show the marks.


With a very light sand with some 120 grit, it is looking much better. I went a bit further after this shot was taken until I was happy enough with it.


Need to smooth out the firewall as well from the same damage.


Was a bit harder due to the pressings as well.


I have well over 200 spot weld holes to fill so need to scrape off the sound deadening panels so the rubber/ bitumen doesn't melt and contaminant the welds.


I noticed the right side had been pulled back as well from the impact. You can see the difference in the jack length that the left one is longer before any tension has been used. The left one is just there to stop the whole lot just twisting. I jacked the right side until both were the same after the tension was released. Got it right on in the end.


The rear most part of the floor had this pressed in which I didn't want. I will be turning up a flange right along where the floor was cut so it can be welded to the rear wall.


A couple of hits with a dead blow did was I was expecting and showed how much extra material I need to work out. Just hamming away at it would only stretch it more so it needs to be shrunk.


Going to try out a shrinking disc for the first time. Not sure if they are made to reduce this amount of material though. They make friction without thinning the steel. Then you quickly used a wet rag or compressed air to cool it and cause the shrinking. Here is a demo of the same one I bought.


Well it reduced the excess noticeably but not enough. Think this was just too much for a shrinking disc. Least I am learning what it is capable of. Might have been better to start with a puckering bar. Have to make one and give that a go one day.


I then used a propane torch to reduce it further but still had a bit left. So cut a slot with the jigsaw and you can see how it closed up along the edge. I welded this closed and the heat from that drew it in even more.


Did one more slot and sitting much flatter. I had also welded up the spot weld holes to help with the shrinking too. Just needs a bit more dressing up and should be good after the flange is folded I think.
__________________

__________________

My web site below:
www.go.jeep-xj.info

Invention is a combination of brains and materials.
The more brains you use, the less materials you need!
Reply With Quote
  #567  
Old 05-25-2013, 08:59 AM
ALPINEST4RS's Avatar
Member
My Jeep: 2007 4.7L WK
 
Join Date: Mar 2010
Location: Brighton, MI
Posts: 340
Thanks: 8
Thanked 0 Times in 0 Posts
Rep Power: 1910
ALPINEST4RS is on a distinguished road
Re: Grand Willys project

Looking good man, alot of talent!!
__________________
[SIGPIC][/SIGPIC]
2006 Jeep Grand Cherokee WK 3.7L - SOLD (lil bro's)
2007 Jeep Grand Cherokee WK 4.7L - 20% tint, magnaflow, afe cai, viper reps, h&r springs, hypertech, trailhawk badge, M/M ed ;)
Reply With Quote
  #568  
Old 06-01-2013, 07:33 AM
Member
 
Join Date: Jul 2010
Location: Australia
Posts: 826
Thanks: 1
Thanked 25 Times in 24 Posts
Rep Power: 1658890
Gojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond repute
Re: Grand Willys project


Dressed it up the best I could so it was better, but not happy with the part closest to the oval hole as has pin holes from welding up the holes that were there.


I cut out that section and replaced it. Welded from the top of one tack and used a short stitch weld to the top of the next one as get less pin holes this way I have found. The top of the patch has been curved to reduce the distortion you get from using a right angled corner. Less concentration of heat this way.


To remove the same pressing on the other side, I simple cut each side of it and then flatten it out. The excess went under the rest of the metal.


Cut the excess away and then welded up the slots. This was much quicker and much less distortion than the other side.


I used the same technique to shorten these ridges as well.


Had a go at hammering around the end of the pressings to make them round like the other end of them.


Now I want to tip a 15 mm flange all the way along the end of the cut floor so it can then be plug welded to the back of the rear wall of the cab. So I grabbed some 35 mm thick chip board that I had cut out when I fitted the new kitchen sink during the renovations inside the house. Just ran a pencil along the floor and then cut along the line using a jigsaw.


Used some sash clamps to fasten it over the end of the floor leaving 15 mm sticking out. I was fortunate that this all needed to be straight. You could curve it though if thinner board was used.


Started in the middle of the straight sections and worked outwards. Only tipping it a small way keeping it even. Clamps were in the way to tip the whole length at once, so did it in sections.


On the outer corners used this more domed head to reduce hammer marks.


This end was used along the straight sections until it was tipped over to about 45*.


Used a flatter hammer to do the last of it. You will always have some puckering on the inside corners where the metal needs to gather. Manufactures some times reduce the size of the flange at the corners to reduce this if needed.


All worked out well and using the board made sure the floor did not change its shape when bending at all the curves.


As the board was a bit short, the last part was bent over separately.


Started to weld up over 200 pilot holes from where the spot welds were drilled out.


To grind down the welds I use a flap disc. No bluing of the metal this way so shows less heat introduced. To get the most out of the discs I grind the edge away to get rid of the worn away paper on the ends. I have both grinders running at the same time and bevel the edge like shown.
__________________

My web site below:
www.go.jeep-xj.info

Invention is a combination of brains and materials.
The more brains you use, the less materials you need!
Reply With Quote
  #569  
Old 06-01-2013, 08:57 AM
jayloop's Avatar
Member
Photobucket

My Jeep: 2005 5.7L WK
 
Join Date: Sep 2010
Location: Knoxville, TN
Posts: 810
Thanks: 6
Thanked 20 Times in 20 Posts
Rep Power: 224220
jayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond reputejayloop has a reputation beyond repute
You need your own tv show! I don't need cable tv anymore with this build thread! Excellent work my friend.
__________________
'05 WK LTD HEMI|...TOTALED
'08 WK HEMI|Mopar CAI|Superchips Flashpaq|SRT8 Front and rear sways|...lots more on the way
Reply With Quote
  #570  
Old 06-02-2013, 04:20 AM
Member
 
Join Date: Jul 2010
Location: Australia
Posts: 826
Thanks: 1
Thanked 25 Times in 24 Posts
Rep Power: 1658890
Gojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond repute
Re: Grand Willys project

Quote:
Originally Posted by jayloop View Post
You need your own tv show! I don't need cable tv anymore with this build thread! Excellent work my friend.
Ha ha, thanks mate.
__________________

My web site below:
www.go.jeep-xj.info

Invention is a combination of brains and materials.
The more brains you use, the less materials you need!
Reply With Quote
  #571  
Old 06-08-2013, 05:51 AM
Member
 
Join Date: Jul 2010
Location: Australia
Posts: 826
Thanks: 1
Thanked 25 Times in 24 Posts
Rep Power: 1658890
Gojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond repute
Re: Grand Willys project

Not much to add this week but thought I might as well put up some thing.


Finished filling all the holes in the floor and firewall. I found the best way was welding them up, using some copper under the larger ones, then flipping it over and tacking any pin holes and low spots. It is much easier doing it this way before doing any grinding as you have more thickness to work with. I would then grind one side flat, tapping down any distortion before then grinding the other side flat. Used just a flap disc but could use a grinder too. Just spent a few seconds on each weld before moving to the next one. After a few come back to the first and do a bit more. This keeps the heat down low and stops it pulling downwards.


Time to visit the old cabs. I was hoping to use the centre of the rear wall from the 48 and its two front corners. The 58 above to provide the the remaining so I could cut each piece larger than stock so when put back together give me the longer and wider cab I want to build. This gives me the smallest number of seams, but there is just too much rust in the lower front corners of the 48. So will use the 48 for the centre both front and rear and the 58 for all the corners. Can make the extra width up this way with only two seams each end but will have to add a separate piece to lengthen the cab.


Here is the front body mounts I need to cut free to add to the donor firewall. Scraped away the dirt and found them still to be solid.

My stash of front guards.
__________________

My web site below:
www.go.jeep-xj.info

Invention is a combination of brains and materials.
The more brains you use, the less materials you need!
Reply With Quote
  #572  
Old 06-11-2013, 01:06 PM
JeepFreak12's Avatar
Black Widow
My Jeep: 2010 6.1L SRT8
 
Join Date: Mar 2011
Location: Roseville, Michigan
Posts: 1,786
Thanks: 131
Thanked 80 Times in 75 Posts
Rep Power: 7856
JeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond reputeJeepFreak12 has a reputation beyond repute
Garage
Re: Grand Willys project

I just spent an hour going thru this build thread. OMG I am jealous! You have some serious skills and this thing is looking sick already. Cant wait to see it together!
__________________
Reply With Quote
  #573  
Old 06-12-2013, 04:10 AM
Member
 
Join Date: Jul 2010
Location: Australia
Posts: 826
Thanks: 1
Thanked 25 Times in 24 Posts
Rep Power: 1658890
Gojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond repute
Re: Grand Willys project

Quote:
Originally Posted by JeepFreak12 View Post
I just spent an hour going thru this build thread. OMG I am jealous! You have some serious skills and this thing is looking sick already. Cant wait to see it together!
Glad you liked it so far.
__________________

My web site below:
www.go.jeep-xj.info

Invention is a combination of brains and materials.
The more brains you use, the less materials you need!
Reply With Quote
  #574  
Old 06-15-2013, 08:17 AM
Member
 
Join Date: Jul 2010
Location: Australia
Posts: 826
Thanks: 1
Thanked 25 Times in 24 Posts
Rep Power: 1658890
Gojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond reputeGojeep has a reputation beyond repute
Re: Grand Willys project


Got the seat riser out and have stripped everything from the firewall on the 58. Taken out the windscreen and rear window etc too. Might be worth selling even?


This is the seat riser. Had the sand the paint away to find the spot welds along the back and flanges.


Was checking to see which front corner to use and a few prods with a screw driver on the 48 and this thick piece of bog fell off! Looks like they had repaired it but did not try to hammer the welds to stretch it back into shape. I will use the corners from the 58 which has less rust damage but still some as you would expect from an old farm truck.


Going to remove the floor braces to transfer them over to the new floor panels.


Decided to throw the donor floor/firewall onto the frame to see how it all lined up.


Can see here the flanged that I turned up. It is nicely parallel with the cross member. I have left a 32mm/1-1/4" gap between the rear of the cab and the cross member.


Have the firewall sitting the exact distance it was in the donor from the back of the heads. The floor is sitting on 1" thick board to get the same gap as the stock Willys had between the top of the frame and underside of floor. This will leave enough room for the stock floor braces to be fitted as well.


Plenty of clearance for the headers on both sides.


Exhaust and the cat shield have plenty of space.


The floor is resting on the fuel tank pads as needed. The cross member clears the floor and the mount lines up under the threaded insert so I can use it as a body mount. The gap is for the rubber isolator.
__________________

My web site below:
www.go.jeep-xj.info

Invention is a combination of brains and materials.
The more brains you use, the less materials you need!
Reply With Quote
  #575  
Old 06-15-2013, 09:58 AM
Dustinmk4's Avatar
Member
My Jeep: 2004 4.7L WJ
 
Join Date: Jun 2012
Location: Northern Utah
Posts: 435
Thanks: 36
Thanked 17 Times in 16 Posts
Rep Power: 1193
Dustinmk4 is on a distinguished road
Re: Grand Willys project

Looking great! Your skills amaze me.
__________________
2004 WJ Limited (The Phoenix), Addco rear sway bar, CAI, super cool firefighter logo seat covers so my kids don't destroy my leather, sct tune from Flyin Ryan, Fat Bob's Garage 2.5"/2" lift, Treadwright 245/75R16 Pumas.
Reply With Quote
  #576  
Old 06-16-2013, 08:23 AM
Madanio24's Avatar
Senior Member
My Jeep: 2005 3.7L WK
 
Join Date: Jan 2012
Location: Eastern Shore MD/NJ/NY
Posts: 1,892
Thanks: 6
Thanked 26 Times in 25 Posts
Rep Power: 11190
Madanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond reputeMadanio24 has a reputation beyond repute
Garage
Send a message via Skype™ to Madanio24
Re: Grand Willys project

WOW Great!
__________________

__________________
Matt
-05 WK Black
Too many mods to list...
-90 Integra GS
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
New Project: Sir Sam Grand Cherokee - WJ 66 06-30-2011 08:15 PM
Next project!!! Black Ops Auto Works Interior/Exterior Visual 57 03-22-2010 10:57 PM
1965 Willys CJ-5A Joe in PA Wrangler-JK 9 01-05-2010 04:08 PM
my new project jeeppro Other Rides 7 11-25-2009 04:55 PM

Powered by vBadvanced CMPS v3.2.3

All times are GMT -5. The time now is 12:30 PM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2014, vBulletin Solutions, Inc.
Copyright 2012 - JeepGarage.Org
The Jeep Grand Cherokee Owners Community