Back into the Willys again after getting everything back into order after being away.
While marking out the cabs I also had to take into account the width of the top part compared to the bottom one once the 2" sectioned was cut out. The taper at the A pillar showed I had to add 3 mm, 1/8", each side. The fill in piece for the top part will be made 226 mm, 9", and the bottom 220 mm.
The B pillar has even more taper as the section to be cut out was a bit higher where it tapers more around the window height. An extra 6 mm, or 1/4" extra each side will be added.
The back wall will mostly come from the 48 cab. It was cut as wide as possible on the lower section to just where the recessed part starts to curve. I will use the corners on the lower part from the 58 and they will be cut further along to make up the extra width that I am after. It will be more than the 220 mm that I am widening the cab because I am also making the cab longer. Due to the trapezoid shape, when viewed from above, means any extra length also makes the rear wall wider. An extra 35 mm, or nearly 1.5" wider.
The upper part of the rear wall will be used completely as is in much better condition than the 58. It will be cut in half and a new piece made for the middle making the window wider.
So after much checking of all the cut lines, it is out with the 9" grinder with a cut off wheel to cut through the pillars.
The switched to the jigsaw to cut the rest around the cab walls.
The reciprocating saw was great for cutting through the header panel as you could keep the cut straight by cutting both sides at once.
Well the top is off!
Wont be using the parts in the fore ground from this cab, only the ones in the background. They will still be useful for cutting out some patch panels where this one is not damaged in the same places.
So the 48 will give up the rear wall, all 4 corners of the top section and the lower middle part of the cowl which have all been been cut 9" wider.
Time to cut up the 58 now. Decided to use the reciprocating saw to cut through all 4 pillars first. Just got to keep an eye out of both ends of the blade to keep it level.
The jigsaw with a fine metal cutting blade was use for the cowl and rear wall.
Cutting out a section of the upper frame above the window to make the rear wall of the 48 cab wider over all.
This piece cut out had a lot to take into account. Not only the extra over all cabin width of 220 mm, but also the 35 mm extra due the the taper of the cab floor from making the cab longer. Then 12 mm total due to the taper in the walls after sectioning out the 50 mm, and then also another 3 mm for the thickness of the blade when I cut the rear upper wall through the middle of the window!
So 270 mm extra in the upper rear wall in the end. I don't expect anyone to follow that rambling.
Another roof chopped off.
Cutting the corners to size.
The parts used out of the 58. 2 cowl sides and rear corners plus the upper and lower sections of the front window and above the rear window as well, though not shown.
I wished I could have done it differently but the lower part of the 58 was in better condition than the 48 and vice a versa. So used as much as possible of the best parts from both cabs and will fabricate parts that were just too far gone in both.