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  #685  
Old 01-27-2014, 04:22 AM
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Re: Grand Willys project

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Originally Posted by NHWK05 View Post
Looking good mate! Now, Is it done yet? Lol
Hope not as having too much fun to have it end already.
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  #686  
Old 02-02-2014, 04:13 AM
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Re: Grand Willys project


This the stock cowl and door together and feel things can be improved for them to better match each other. The cowl looks rather plain stock next to all the detail in the door.


Firstly will extend the door sill pressing all the way to the end and then thinking of adding this Willys pressing to line up with the middle of the three ribs at the bottom of the door. Similar to what you find on a CJ5 etc where they have Jeep instead.


Also have to add an intake for the A/C so fresh air can be sucked into the cabin. Got a pair of louvers sent to me before the scrapper took the rest of the FJ Landcruiser tub.


Beat out the folds it had and cleaned it up. I will be adding one to the other side as well as will be needed to make up the volume I need. Will be a bit more than required so thinking of removing one louver to leave 6. That matches better with the two lots of three ribs on the door as well. The bottom louver will line up with the top of the guard/bottom of the bonnet/hood. The cowl seam will be welded up as well as does not line up with anything at all.


Got a fair bit of work to do to repair the rust here at the bottom of the cowl on both sides. Will be able to get rid of most when extending the door sill pressing to the end and will cut away the factory joint which is all twisted and full of lead. There is also a patch that has to be cut out where the original mirror I think was ripped out leaving a big hole. That was later fixed by them backing it with some 1/4" plate and arc welding it to the panel steel! Caused a lot of distortion and fatigue cracking.
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  #687  
Old 02-03-2014, 08:53 AM
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Re: Grand Willys project

Thanks for the update! I was beginning to worry that perhaps medical issues had kicked back in.
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  #688  
Old 02-04-2014, 03:08 AM
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Re: Grand Willys project

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Originally Posted by sonofasailor3 View Post
Thanks for the update! I was beginning to worry that perhaps medical issues had kicked back in.
Just busy working on the house and suffering the 100*F temps here at the moment.
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  #689  
Old 02-09-2014, 11:24 AM
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Re: Grand Willys project

Awesome man, glad to see you're still working on this build. I remember when it started in 2011 and I was like how the heck is this gonna come together. But like anything, with som time, effort and patience anythings possible I guess haha.

Almost there now, think she'll be on the road this summer or I guess winter for you??? Haha
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  #690  
Old 02-10-2014, 03:04 AM
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Re: Grand Willys project

Glad you have stuck by it so long and be at least that more time still to go! The build is like going on holidays. Some just want to get to the destination as fast as possible, but I'm one that likes the journey there, some times more so.
Doesn't always include sitting in economy for 30+ hours though!

We have has extreme heat here with total fire bans which also include all welding and grinding work etc. So that has taken some time away too.
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  #691  
Old 03-01-2014, 05:42 AM
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Re: Grand Willys project

Haven't had as much time of late and a lot of little stuff that needs to be done is not worth showing like repairing the hinge pockets and welding in little patches here and there etc. Just thought I would put up a bit to show some thing is happening anyway.


This ugly repair needs to be cut out as the heat warped the whole panel and cracking around it from fatigue has occurred.


I reduced the amount of louvers by one and now laying it out and the Willys pressing to be square with the door edge.


This is what the back of the nasty repair looked like.


I want to do a better job of this junction too.


I welded the whole cowl seam just with the mig and then cut the flange off the back so I could planish it flat. Also made a patch for the repair spot after shaping the piece with a mallet on the beater bag.


Fully welded and the louver is just sitting there as will leave that until last so it does not get damaged when the rest of the repairs get done.


I started with the worse side of the cowl first so I had something to reference back too. The other side showed this to be flat but this was already bowed before starting any repairs, most likely from the arc welded patch at the top.


Using mainly the shrinking disc on the 9" grinder, and then cooling straight away with compressed air, I was able to get it quite flat again. As more repairs get done it will have to be repeated again a number of times no doubt.
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  #692  
Old 03-01-2014, 05:50 AM
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Very nice. Good to see you back in the saddle so to speak.
That set square looks ancient. Where did you dig that up from.
Can't beat old tools though, very tactile.
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  #693  
Old 03-02-2014, 02:39 AM
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Re: Grand Willys project

The set squares are older than I am for sure. Found half buried on a earthen floor some where from memory. Actually I recently put both squares through the citric acid bath so all the rust would not cover my hands every time I used them. Can even read them now and didn't even know one of them had any thing on it it was that bad!
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  #694  
Old 03-02-2014, 04:31 AM
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Re: Grand Willys project


Melted the lead out of the sill join and was not pretty. Will cut it all away and remake the whole bottom section.


Tacked in the Willys pressing ready for tig welding once I get one.


Folded up a replacement for the bottom of the cowl with the extended sill all the way to the end this time.


Used the rounded flipper to create the curve by hamming down on it with the mallet. Was easier than trying to hammer down under the lip with the flipper alone.


Ready for welding.


Dressed and ready to fit.


The inner panel needed repairs as well.


Replaced the bottom section and thought the pitted area above it looked bad by comparison now so cut it out.


So that has been fixed now ready for service once again.


To make sure I got the holes for the running board in the right place in the new piece of the bottom of the cowl, I clamped it together with the guard. Gave me an idea of how it will look together now too. Can see how I lined up the bottom of the louvers with the top of the guard as well.
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  #695  
Old 03-03-2014, 11:54 AM
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As always your skills,determination,and perseverance are very impressive. I can imagine when it's done there will be mixed emotions,elation to have completed it, and some sadness as this project comes to a close. But I guess it's on to the next thing. Do you have children or any neighborhood kids that take a fancy to this work? It would be great to impart some of your vast knowledge and wisdom on down to them. Thank you very much for all the additional effort that it takes to not only perform the work but to then sit down and document and photograph it as well. My hat is off to you sir.......
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  #696  
Old 03-04-2014, 04:45 AM
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Quote:
Originally Posted by kennzz05 View Post
As always your skills,determination,and perseverance are very impressive. I can imagine when it's done there will be mixed emotions,elation to have completed it, and some sadness as this project comes to a close. But I guess it's on to the next thing. Do you have children or any neighborhood kids that take a fancy to this work? It would be great to impart some of your vast knowledge and wisdom on down to them. Thank you very much for all the additional effort that it takes to not only perform the work but to then sit down and document and photograph it as well. My hat is off to you sir.......
Thank for your comments. Only have a daughter and not interested in learning the skills. Not even her fiance, who is a mechanic, has bothered to want to learn. Just too proud to admit that I might know some thing he doesn't!
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