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  #673  
Old 11-19-2013, 03:10 AM
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Re: Grand Willys project

Quote:
Originally Posted by dudefromflorida View Post
That will be a good addition. I love little things like that put into builds. It really makes things stand out and shows that people who do it have an eye for custom items.
Glad you appreciate it too.
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  #674  
Old 11-20-2013, 12:20 PM
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Re: Grand Willys project

2 years of amazing work. Keep it up!
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  #675  
Old 12-14-2013, 06:30 AM
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Re: Grand Willys project

Been busy working on the house, garden and the Cherokee lately but have managed to still get a bit done here and there when I could. Also have stripped all the paint from the lower half of the cab and dipped it in the citric acid to remove the rust. Didn't think it was worth boring people with showing that as have already shown the process.


I placed the part of the CJ2a tailgate under the hole cut away from the old vent and marked where to cut. The WILLYS name was centred exactly over were the old vent was and then tacked it into place. Was about to fully mig weld it in but decided against it due to cracking problems when you hammer the weld to get rid of any distortion. So going to buy a AC/DC tig welder and learn how to use one. Always wanted to learn so this is a good time to do so. Been watching plenty of videos on it and reading on forums so wish me luck.


This is where the panel will sit. I left the reduced height at the top of the raised part that the stamped Willys is on as it looks more factory blending into the cowl as is rises.


This also gives you an idea of how I plan to join the old cowl to the new firewall. The old part of the Willys firewall will be replaced with a single piece that will take in the whole width of the firewall and the three parts of the cowl. It will also have a bottom flange turned up so it can be plug welded along the existing seam there. Will most likely make a hammer form as both top and bottom flanges are curved.


Spent a bit of time smoothing out that dent further that I had worked on earlier. Used a file to highlight the highs and lows and then worked it with the slapping file and shrink disc.


Just about got it now.


Got this rotted out corner to repair. I have melted out the factory lead to see just how much needs to be done.


Can see the door sill has a hole right through it as well as poor alignment of the joint too.


Traced the end of the sill to get a profile so I can make a patch panel for it.


It is important when laying out a lot of folds like this that the thickness of the metal is deducted for each fold. This is 1.2 mm sheet and if I did not take the thickness into account, I would be out 7.2 mm by the end.


The sill is not flat between the folds so it is easier to get the profile in before folding. As I don't have an english wheel, I just used a convex slapper/flipper on the beater bag to get the shape.
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  #676  
Old 12-14-2013, 12:10 PM
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Re: Grand Willys project

Thanks for the update. We've been patiently waiting.
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  #677  
Old 12-15-2013, 03:32 AM
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Re: Grand Willys project

Quote:
Originally Posted by sonofasailor3 View Post
Thanks for the update. We've been patiently waiting.
I'm glad.
Continuing on.


Curve now matches, so on to the folding.


Put a bit of a radius on the edge on my table and clamped down the piece. Then used a flipper to knock in the fold as leaves no marks like a hammer would. A soft blow hammer or rubber mallet works well too.


Used a bolster with the closer folds.


Just needs a slight adjustment and be ready to weld in.


A little trick too is if you have a folder that is not adjustable, you can soften the fold by folding a piece of scrap first and then placing the next piece under it.


Welded in and ready to be trimmed to fit.


Looks better than the factory join above it.


Before fitting the sill back I need to repair the rusted out piece just above where it will go.


Welded in and will give it a final trim once I start fitting the sill back in. The raised part is the end of the lower sill.


Important to keep it nice and straight as the back of the door edge will be running along side of it.
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  #678  
Old 12-18-2013, 03:00 AM
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Re: Grand Willys project

Had a few photos left on the memory card so thought I would put them up before we leave for holidays on Friday.


Welded the sill back into the panel. I welded it from the inside as hard to smooth out the weld on the inside corners otherwise. Had to take into account the angle of the sill that is for the same as before to not only match the door, but also that it pointed towards the A pillar.


The sill is made from 1.2 mm/18G and the panel from 0.9 mm/20G. The join from the factory was in line with the edge of the B pillar but I extended the sill into the end of the original panel pressing instead. Be stronger this way.


The other side was not as bad but was very thin and could not easily tack a few pin holes. Want to clean up that factory join anyway so did the same to this side as well.


Both sides done now.
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  #679  
Old 12-18-2013, 05:33 AM
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Lovely step by step work through. May thanks and Happy Holidays.
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  #680  
Old 01-08-2014, 08:54 PM
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Re: Grand Willys project

I know youve been busy, but any updates?
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  #681  
Old 01-08-2014, 09:11 PM
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Re: Grand Willys project

^^^ x2!!
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  #682  
Old 01-11-2014, 06:36 AM
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Re: Grand Willys project

Only been home for a week and worked on the XJ. I have to start back on the house renovations next week.
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  #683  
Old 01-23-2014, 07:02 PM
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Re: Grand Willys project

Just a video of where it was last left at.



Hope to get back into it soon.
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  #684  
Old 01-26-2014, 02:24 PM
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Re: Grand Willys project

Looking good mate! Now, Is it done yet? Lol
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