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  #589  
Old 06-24-2013, 04:35 AM
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Re: Grand Willys project

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Originally Posted by cheapjeep View Post
I see where you're coming from on this,Marcus. I would definitely keep the center bar also. To me its an integral part of the "look" of the Willys.
I agree with you there 100%. Think it looks more old school, or hotrod, with it. Same reason I will be running the smaller 48 rear window too instead of the 58's.
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  #590  
Old 06-24-2013, 09:26 AM
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Re: Grand Willys project

So happy to see the route your taking for the roof chop. I am not a fan of the dis-proportioned windows... I am too OCD for that. Also, I feel it looks like a shortcut was made when hotrods and customs runs that look.

Great job on the build!!
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  #591  
Old 06-24-2013, 03:19 PM
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Re: Grand Willys project

Gotta keep the bar!
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  #592  
Old 06-29-2013, 06:54 AM
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Re: Grand Willys project

Not much to show in the way of progress this week as went to a car hill climb event and spent some quality time with my wife. She has been painting inside the house nearly every weekend since January, so time for a bit of a break.

Hopefully I wont bore you with some set out photos for the chop.


You would think it would be easy marking out a 50 mm/2" section to remove to lower the front screen and roof down by. It is if perfectly vertical. But the front of the cab is not as has a compound curve right across the front as curving in both directions. Also the steepness changes as well which effects it again. It is steeper at each end compared to a shallower angle in the middle. So to get the same vertical drop evenly right across, the amount to cut out when measured flat along the steel face, will be less at the ends and more out of the middle. None of it will be 50 mm/2" as not vertical anywhere. I thought the easiest way to do it was use a laser level and spent time setting it up perfectly level and then levelled the cab with it.


You can see along the cab where I marked the top of the laser dot every 20 mm or so. To get the lower mark I simply held the ruler exactly vertical and with the top of the dot at 50 mm/2", then marked at the bottom of the ruler. Lowered the laser level until it lined up with the lower mark and repeated the marking for the bottom line.


Bit hard to see because you are fighting perspective here, but the lines are not parallel and get further apart in the middle compared to the steeper ends where it is closer together. Just got to see it as a right angled triangle. The sheet metal is the hypotenuse. As the angle changes, but keeping the same vertical height, the length of the hypotenuse alters. Ended up showing a 8 mm-5/16" difference between the middle and ends. That would have been a lot of extra grinding had I just ran some 2" tape along the front!


When it came to going around the corner, I will cut at the upper level line so I can stay above the change in angle from the lower vertical to the angled screen.


Unfortunately I can't cut all the way through the pillar at that height as would end up above the window sill around the back. It will have to be stepped down at one point.


To see where the best place to cut was I found it necessary to remove the welded in dash. Was quite a job getting it out as could not see the spot welds up under the dash holding it in or get a drill up in there anyway.


Can see a made a bit of a mess with the air chisel so this piece will need to be repaired or replaced.


Fortunately the damaged piece needed to be removed anyway so I could see the best way to cut a section out. Also this is the only way I would be able to weld it all back together again and get full welds on every face. As the outer skin wraps around this pillar on the outside creating two layers, there would be no way to weld the inner pillar face without cutting a piece of the body away or accessing it like this.


I have got some damage to repair as well as looks like a big gust of wind caught the door, or it was let go on a steep side angle at one point. It ripped the door stop attachment point clean out and then caused the tearing of the hinge hole and a long crease all the way down the panel. Access is going to be difficult as the pillar is in the way on the inside and only a small gap in-between.


The top of the roof has a bad section above the door opening too. I have decided to wait with cutting this cab apart until the other one is stripped as well and see if I can mix and match the best parts possible in the lengthening and widening process.


Another hack job found where a plate was held behind the hole and then arc welded and filled with bog. Want to weld shut this cowl seam anyway as its position does not line up with anything like the top of the guard or bottom edge of the bonnet. The very first year of production in 47, the year before my 48 cab, the factory did not have this seam. Not sure if the cowl was pressed as one or they joined it by another method or just leaded over it? Every cab from 48 on has this seam.
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  #593  
Old 06-30-2013, 05:45 PM
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Re: Grand Willys project

Looks like alot of work ahead of you. Cant wait to see a wk interior in this truck! Shes gonna be sweet when done! This thead will never die! This is the best episode of trucks ever only 100 times better and done better!
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  #594  
Old 07-01-2013, 03:59 AM
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Re: Grand Willys project

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Originally Posted by NHWK05 View Post
Looks like alot of work ahead of you. Cant wait to see a wk interior in this truck! Shes gonna be sweet when done! This thead will never die! This is the best episode of trucks ever only 100 times better and done better!
Ha ha, hope it lives up to your expectations.
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  #595  
Old 07-01-2013, 03:49 PM
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Re: Grand Willys project

Im sure it will!!!
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  #596  
Old 07-02-2013, 11:28 PM
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Re: Grand Willys project

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Im sure it will!!!
X2 on that!
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  #597  
Old 07-06-2013, 05:27 AM
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Re: Grand Willys project


Been having a hell of a time stripping the 48 cab. There are just so many more welds in places that the other cab never had. Also made worse when a rough floor repair has been welded straight over the top of the factory spot welds so have to try and cut away that first. Even the roof skin was harder and this photo shows the 48 leaning in front of the 58 one. There are just so many more spot welds as you can see. The 58 cab roof skin had 89 spots welds, but the 48 had 206! Maybe what stopped it from rusting as the upper half is in way better condition, but afraid the lower half is riddled with rust.
So will try and use as much from the upper 48 cab as I can to replace the rusty upper section of the 58.


Got some FJ40 Landcruiser vents and cast hinges to use in my build. Also the two pieces along the bottom are the Willys floor stiffeners.


Just showing a close up of a before picture as going to try stripping the rust.


Another before shot.


I am soaking the rusty parts in pure white vinegar to try out. Cider vinegar is supposed to be a bit better but costs a lot more. Didn't buy quite enough so will add more. Can already see a difference after 2 days.


After just 2 days as the angled line shows where it was immersed to. Some pieces showed more change than others this early.


Was told citric acid works well diluted in water with one 75 gram, (2.6 oz), container to about 10 litres, (10 qt), of water. Thought I would try some thing different and use the same ratio but added to the white vinegar instead.


So the next 4 shots are after 2 days just with white vinegar and then another 2 days with citric acid added as well to it for a total of 4 days.


Looks just about done already! The only thing I did was scrub the pieces with a old washing up brush once a day for a few minutes.


Will give it one more day and then wash with water with some bi-carb soda to neutralise the acid. Followed with a fresh water rinse, dried with an air gun and then coated in some lanolin to stop it flash rusting. Could use WD40 or fish oil which is the main ingredient, etc too.


The hinges were very stiff to move before and now move freely. Haven't been able to get out the screws yet so might need some heat.
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  #598  
Old 07-06-2013, 07:34 PM
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Re: Grand Willys project

Damn that is an awesome trick!
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  #599  
Old 07-09-2013, 03:21 PM
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Re: Grand Willys project

Wow thats a great trick!
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  #600  
Old 07-09-2013, 05:31 PM
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Re: Grand Willys project

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Wow thats a great trick!
The vinegar bath for rust? Old news. Old school BMX guys have been doing that for decades.
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