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  #769  
Old 11-01-2014, 08:35 AM
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Re: Grand Willys project

This is an amazing thread! You have some serious skills. Lots of work but going to be so worth it!

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  #770  
Old 11-02-2014, 03:25 AM
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Re: Grand Willys project

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Originally Posted by lll2for3lll View Post
I can't remember if you are going for a complete stock classic look or classic/modern. Like slammed and chopped.

???
From the distance it will look 1948, but inside and underneath it will look 2008. Wont be sitting near the ground but a bit lower than stock. No shaved door handles and smoothing features, I like the ribs in the panels etc.
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  #771  
Old 11-02-2014, 03:26 AM
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Re: Grand Willys project

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Originally Posted by moeman View Post
This is an amazing thread! You have some serious skills. Lots of work but going to be so worth it!
Thanks mate.

This is the place I bought the shrinking disc from in case anyone was interested. http://www.rodsandrelics.com.au/site...iscs&sub=tools
Little demo he has.
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  #772  
Old 11-30-2014, 09:27 PM
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Re: Grand Willys project

Well hope to have more to show soon but have just finished another lot of house renovations, so more time now for the project. Nothing photo worthy yet though as just going over the front cowl sides before I can fit them to the firewall. My skill level is getting better so improving on what I thought was finished before. Thought it might so left fitting these for as long as I could.


Just showing how I modified the back of a dolly I had made to make it much easier for getting long high spots down without stretching. I was having trouble picking the right amount of distance for the dolly to be away from where you where hitting when doing the off dolly technique. Also which side of the high spot to place it as often needed it both sides at once. Now just place the hollow in the dolly under the high spot and use a low crown hammer to hit it down without actually directly hitting on the dolly itself. Works really well.


I had some dimples to work out as well and just grabbed one of my roller skate wheels. It supports it all around the dimple and spot any stretching of the metal. I have since just learned that it actually will shrink at the same time and can buy properly made ones for the task. They call them donut dollies and are made of plastic. There is a youtube videos on it. Nothing new under the sun.

I also tried heat shrinking using the tig as a heat source but didn't go as well as I hoped. You can see the dimples it left and why I thought of a way to get them flat again using the skate wheel. Got it pretty good after this photo was taken.
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  #773  
Old 12-08-2014, 07:40 PM
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Re: Grand Willys project

WOW, awesome stuff man! Can't believe i'm just seeing this
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  #774  
Old 12-09-2014, 02:17 AM
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Re: Grand Willys project

Thanks mate. Still working away at it but the fine turning of panels are not picture worthy.
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  #775  
Old 12-13-2014, 05:26 AM
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Re: Grand Willys project


Spent quite a bit of time getting the panel right before zinc coating everything and welding in the A pillar. Next was the bracing for the backside of the cowl.


All welded in but had to do more hammer and dolly work to get it all back to right again. Not from the welding heat so much, but the panel being now ridged on the A pillar and brace.


I had already replaced the lower part of the other side cowl brace and had left this side as was so much better. Now thinking it might not last the next 20 years so might as well replace this side too.


Made a new piece and then cut off the bad section.


Tig welded the old and new together. Getting better at it considering I am still on my first bottle of gas and tungsten. This was done in one pass fusion welded, except a couple of spots where I added some mig filler wire which I always have on the ready as I am going along in case it starts to blow through.


Came up pretty flat after some plashing with a hammer and dolly.


I was double checking all the the B pillars to make sure they were in alignment with the A pillars. I noticed this side curved away from the ruler just near the top.


How ever the other side did not! So which one was right? Checked the curvature of the door and this side was wrong. It is also the side that had been hit. I had ready straighten it in the other direction which needed to be straight, but didn't think to check in this direction to see if it needed to be bent!


I had to free the support brace from the pillar and then I made a cut where it needed to be bent on both sides of the U shaped pillar. Not all the way through to the third face though. Then put a sash clamp and pulled the bend into it. I stopped 0.5mm short compared to the other side, as the welding heat will pull it some more.


After welding the two sides now match perfectly. It pulled that extra 0.5mm.


Fitted the door temporarily to get the right angle of the A pillar. Can see how much longer I have made the cab here too compared to stock. An extra 177mm or 7".


The bottom of these cabs slope inwards so had to makes sure it matched with the B pillar.
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  #776  
Old 12-13-2014, 02:54 PM
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Re: Grand Willys project

Fantastic
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  #777  
Old 12-13-2014, 03:07 PM
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Quote:
Originally Posted by Gojeep View Post
Spent quite a bit of time getting the panel right before zinc coating everything and welding in the A pillar. Next was the bracing for the backside of the cowl.

All welded in but had to do more hammer and dolly work to get it all back to right again. Not from the welding heat so much, but the panel being now ridged on the A pillar and brace.

I had already replaced the lower part of the other side cowl brace and had left this side as was so much better. Now thinking it might not last the next 20 years so might as well replace this side too.

Made a new piece and then cut off the bad section.

Tig welded the old and new together. Getting better at it considering I am still on my first bottle of gas and tungsten. This was done in one pass fusion welded, except a couple of spots where I added some mig filler wire which I always have on the ready as I am going along in case it starts to blow through.

Came up pretty flat after some plashing with a hammer and dolly.

I was double checking all the the B pillars to make sure they were in alignment with the A pillars. I noticed this side curved away from the ruler just near the top.

How ever the other side did not! So which one was right? Checked the curvature of the door and this side was wrong. It is also the side that had been hit. I had ready straighten it in the other direction which needed to be straight, but didn't think to check in this direction to see if it needed to be bent!

I had to free the support brace from the pillar and then I made a cut where it needed to be bent on both sides of the U shaped pillar. Not all the way through to the third face though. Then put a sash clamp and pulled the bend into it. I stopped 0.5mm short compared to the other side, as the welding heat will pull it some more.

After welding the two sides now match perfectly. It pulled that extra 0.5mm.

Fitted the door temporarily to get the right angle of the A pillar. Can see how much longer I have made the cab here too compared to stock. An extra 177mm or 7".

The bottom of these cabs slope inwards so had to makes sure it matched with the B pillar.
You got a door! Slowly but surely its coming together and cant wait for more.
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  #778  
Old 12-14-2014, 03:32 AM
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Re: Grand Willys project

Not so long to wait this time.


Time to get the longer centre part of the cowl to fit in. Can see it has too much curve so there is a dip where the join is.


The other side has a dip and also the bead does not line up.


Can make out the soft 'M' profile that will have to be altered to get it to flow with a fair curve.


Shows the dip better.


I will flatten out the centre section by hammering over the roller skate wheel. The metal needs to shrink as it is flattened and this hopefully will allow me to do that. I already had one failed attempt at flattening this piece a few months ago and ended up with a locked in oil can that I just could not get out. I had just used a slapper down over a beater bag and that was my mistake.


Just moving the panel over the roller skate wheel while hammering over the centre of it is working really well. Slowly getting a controlled shrink. Left side in the picture looks about right now but more needed on the right.


This side still needs a bit more.


This side nearly there and can see I have also aligned the bead now. The area around the Willys stamping is sitting a little high though and will need to be addressed.
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  #779  
Old 12-15-2014, 02:08 PM
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Re: Grand Willys project

Since you appear to be hammering this thing out of raw sheet metal and old aluminum cans, can you share a bit about your experience? Were/are you a professional metal fabricator? An elementary school English teacher with a knack for metal work? An enthusiastic hobbyist? Hang out with Dad in the shop in the years long gone?

I'm just curious, these aren't skills you pick up off of youtube in a weekend.
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  #780  
Old 12-16-2014, 01:31 AM
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Re: Grand Willys project

Quote:
Originally Posted by whartung View Post
Since you appear to be hammering this thing out of raw sheet metal and old aluminum cans, can you share a bit about your experience? Were/are you a professional metal fabricator? An elementary school English teacher with a knack for metal work? An enthusiastic hobbyist? Hang out with Dad in the shop in the years long gone?

I'm just curious, these aren't skills you pick up off of youtube in a weekend.
First trade was a farrier, then boiler maker, and then mechanic. Rest was learned of youtube and forums and just trying things out.
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