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  #781  
Old 12-16-2014, 07:44 AM
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Re: Grand Willys project

Then you are a true Renaissance Man! Great work! We all live vicariously through your postings. Thanks for the updates!

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  #782  
Old 12-16-2014, 02:28 PM
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Re: Grand Willys project

Quote:
Originally Posted by sonofasailor3 View Post
Then you are a true Renaissance Man! Great work! We all live vicariously through your postings. Thanks for the updates!
Yup, so much this.
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  #783  
Old 12-17-2014, 03:12 AM
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Re: Grand Willys project

Why thank you gentleman for saying that!
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  #784  
Old 12-20-2014, 05:19 AM
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Re: Grand Willys project


Can see the low spot I have to address on this side.


Also this best shows how the front part is sitting too high around the Willys pressing and needs to come down.


The same profile taken from the opposite side shows up the low spot here.


Using this dolly I made not on the end as shown, but down at the Willys stamping to get it down. I make sure I only hammer over the dip in the dolly. Did actually use it to raise the low spot at this end too, but with the piece turned over.


Can see how it is come down nicely. I have had to bend the card as the curved part on the right angles in toward the left to form the V shape for the windscreen.


Looks a lot better now and double checked using a laser level to make sure it was level left to right at the joins.


With the area around the Willys stamping now down, it flows better.


The other side is pretty good now too and will do the final tune up of both sides once welded.

Last update for the year as off camping. Will be taking some tools and metal with me though to play with to stop me getting bored.
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  #785  
Old 12-29-2014, 02:53 PM
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Re: Grand Willys project

Epic job. Still watching and learning. Thanks and enjoy your trip.


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  #786  
Old 01-10-2015, 06:43 AM
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Re: Grand Willys project

Quote:
Originally Posted by UKWK View Post
Epic job. Still watching and learning. Thanks and enjoy your trip.


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Thank you.


Set up a little work station under the side awning facing the river of our first bush camp. With a solar panel keeping a fridge running for cold drinks and no one else camping in the whole National Park, was a great place to be.


Dragged a red gum stump that was washed down in the last flood to use as my work table. Starting with a low quality reproduction early Jeep CJ grille I pick up off eBay second-hand. Had never been fitted as would take a lot of work to make them usable.


For a bit of fun and practice, thought I would add some details that was factory pressed in on the later CJ grilles. They had a step down reveal around the headlight hole. So cut some scrap ply that was the thickness of the depth of the reveal I wanted. Backed that up with some chip board.


Screwed the two together and then down to the stump.


From Metalman Sweden, I bought a set of his chaser/caulking tools that had arrived just before we left for these holidays.


Clamped around piece to chip board over the top to keep it flat and not move around. Then started the bend by tapping slowly around the perimeter.


When the edge touched the back board I stopped.


The switched to the wedge shaped piece.


Did blunt off quickly but was still going alright. As he says, it is better than leaving a lot of tool marks and have it softer and then resharpen it. The steel might not have been the softest either being hot rolled galvanized steel from Malaysia and 1 mm/19 ga thick. There was tearing where they had pressed the top of the grille slots.


I had a rounded steel cold chisel with me so switched to that to get it a bit sharper. Was worried the other might blunt off too much and had no real way to sharpen it for the other side. This did leave tools marks though as you can see.


Did use the caulking tool to smooth out the tool marks left as best I could from the cold chisel.


Use the flat end piece to get it to sit down level.


One side down and one to go.


Both sides now done. The wedge piece did not blunt off much more so could have avoided a lot of tool marks if I had used only that. Still that was what this was about, learn on something that didn't really matter.
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  #787  
Old 01-11-2015, 04:19 AM
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Re: Grand Willys project


Next camp site I made a work area from part of a fallen red river gum that someone has chainsawed this flat area in. When I got too hot from hammering, I just dropped into the river to cool off.


To try something else, I thought I would add some features where the parking lights normally go. Placed them a bit lower than stock to give a bit more balance. I cut the holes out with a jigsaw I had with me.


Made these hammer forms up so I could make a lip around the hole to make it look more finished and adds some strength as well.


Used the thicker chip board this time on the back and the ply to hold it flat. Didn't want it too thick on top to make easy access.


Started the bend again with the mallet and then used the wedge piece on the chaser tool.


Just worked my way around it a bit at a time.


Got my wife to hold the grille over a fence post to get better support under the form.


Checked the underside to see how close it was getting. Nearly there.


One side done.




The angle of the shot makes the depth look uneven, but it was not.


Now both completed


Next camp we had I found a tree where I could wire up the grille and hit it with some etch primer. As it is galvanized, couldn't use normal primer.


Some rattle can red for a top coat. Unfortunately, on the way home in 43*C/110*F heat, I had it under the cover of my camper where it wouldn't get scratched. But the cover stuck to it so it had to be redone again.


Sanded the imprint of the trailer cover off it and repainted it. No plastic or primer filler was used at all on it before painting. It is just some wall art for my workshop.


It has good company with Willys and Jeep grilles from 1942 to 2008. The 42 MB grille is out of shot, then follow by a 48 Willys truck, 58 Jeep truck, the CJ grille, chrome cover piece off a 98 TJ Wrangler and can just see a 2008 JK Wrangler grille.
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  #788  
Old 01-11-2015, 04:53 AM
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Re: Grand Willys project

A. You have a very understanding Wife
B. You made me chuckle taking that camping.
C. You really do have an understanding Wife.
Lol


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  #789  
Old 01-12-2015, 04:58 AM
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Re: Grand Willys project

Quote:
Originally Posted by UKWK View Post
A. You have a very understanding Wife
B. You made me chuckle taking that camping.
C. You really do have an understanding Wife.
Lol


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Ha ha, all good.

Last of the camping photos. Hope I didn't over do it with them.


For something else to play with while away camping, I thought maybe try to see if I could make my own pressing. I did a pencil rubbing of one of the cowl pressings before I left.


I wanted to see if I could make the project name up of Grand Willys, but struggled to find a similar font to make the Grand name. So started to play with a script instead along the lines of what is pressed into the bumper.


Found using some melamine board I had with me worked well as could use it like a white board and wipe off parts I didn't like.


Once I got one I liked on the board I needed to transfer it to some paper. Just placed the page over the board and traced over it.


I needed a reverse image for transferring it to the steel. Some of the pencil had transferred to the back of the page when I did the tracing. So just went back over it to make it clearer.


Placed it over the scrap steel and drew back over the name which will transfer the pencil on the other side to the steel


Here you can faintly see how the pencil from the back of the page transferred.


Went over it with a marker to make it easier to see.


Had a round piece of rod with me and just started hammering on the first letter to see if it would work. I hammered over a piece of rubber.


Can make out the pressing on the other side


Completed the first part of the name.


Did the other half


At an angle might show it better.


Using a block sander over it showed the unevenness. Maybe with more work you could get it even? But this was just scrap and gave me something to try out while camping.
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  #790  
Old 01-12-2015, 12:35 PM
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Re: Grand Willys project

Quote:
Originally Posted by Gojeep View Post
Ha ha, all good.



Last of the camping photos. Hope I didn't over do it with them.





For something else to play with while away camping, I thought maybe try to see if I could make my own pressing. I did a pencil rubbing of one of the cowl pressings before I left.





I wanted to see if I could make the project name up of Grand Willys, but struggled to find a similar font to make the Grand name. So started to play with a script instead along the lines of what is pressed into the bumper.





Found using some melamine board I had with me worked well as could use it like a white board and wipe off parts I didn't like.





Once I got one I liked on the board I needed to transfer it to some paper. Just placed the page over the board and traced over it.





I needed a reverse image for transferring it to the steel. Some of the pencil had transferred to the back of the page when I did the tracing. So just went back over it to make it clearer.





Placed it over the scrap steel and drew back over the name which will transfer the pencil on the other side to the steel





Here you can faintly see how the pencil from the back of the page transferred.





Went over it with a marker to make it easier to see.





Had a round piece of rod with me and just started hammering on the first letter to see if it would work. I hammered over a piece of rubber.





Can make out the pressing on the other side





Completed the first part of the name.





Did the other half





At an angle might show it better.





Using a block sander over it showed the unevenness. Maybe with more work you could get it even? But this was just scrap and gave me something to try out while camping.

That's awesome man!


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  #791  
Old 01-17-2015, 05:53 AM
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Re: Grand Willys project


Bought a cheap bead roller that I will start using next. But before I do I wanted to modify it already from what I have read others doing to make them better. One of the things on a manual roller it is easier to turn a wheel rather than the crank handle they come with when by yourself. Normally they use an old steering wheel but I had given away my old Willys one, so thought maybe a Jeep wheel instead?


The bead roller shaft is only 25 mm and didn't have any pipe that size so slowing filed out a threaded pipe collar to fit. But now have to make up the difference in size between the wheel and the pipe.


Remembered I still had a good hub that is actually from the same Jeep as the wheel.


Cut the outer part off as wont work with it rotating.


Cut it down to size and will weld the pipe to the back of it.


Cut the wheel centre off the rim. These don't join in the well like most so was able to keep as much diameter as possible.


The hub flange was welded on to the collar and a nut too. Tapped through the nut into the collar for a bit of extra strength. Can see the simple stand I made too so it clamps into my portable vice at the right height.


Other things I did was add a spring from a bed base to pull up the top shaft to make getting the sheet in and out easier. Can also see I got rid of the little adjusting screw and drilled and tapped the steel for a bigger old spare wheel hold down screw.


Made my own fence/guide for is as well. Has a removable centre section held down with thumb screws for when you are behind the pillow blocks.


The guide is tool less as well as used a fastener from some gym equipment I found thrown away. Always grab them when I see them


Using pieces cut from the 58 Willys chassis rails, I reinforced the bead roller main plate. Before I could twist the ends of it with just my fingers! I placed the reinforcement pieces over the shafts so that the roller is not made any wider, which will be handy if rolling any tube etc


Made my own tipping dies using a roller skate wheel, which happen to have the hole size the same as the shaft, where the bearing was. Just pushed in a thick washer on the outside of the wheel. The top die was just a hardened large washer I had. May have come from an old 70's Range Rover front top shock mount or the chassis end of the radius arm? Had to make a little sleeve to match the bolt size. This setup will allow me to bend a flange on a curve.


Wheel bolted on. Even fitted the centre cap.


Fitted the handle after drilling and tapping the wheel and using a lock nut on the back to hold it. Will come in handy when the wife is turning the wheel. Strangely I prefer to pull the wheel towards me when feeding the metal through the rollers so switch the shafts so it ran that way. When using the crank, I prefer the other way?
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  #792  
Old 01-18-2015, 04:15 AM
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Re: Grand Willys project


I ended up swapping the wheel around so it was closer to the rollers making it easier to use. Looks like a dually wheel now!


Made a quick run of the different bead die combinations I can make. Only have the three different profiles but mixed them all up to see what I could come up with. The width doesn't change on the same sized lower die, but there is a difference in shape and height of the bead. Last three on the left were with the roller skate wheel.


Was playing with the bead roller using a roller skate bottom wheel with the three bead profiles I had. Pay no attention to the patterns themselves as was just playing around and was all free hand.


Was hoping to put the W O from my tailgate in scale on the top of my firewall where I have to make a new fill in piece. Once I had scaled it down I realised it would be too small to look any good.


Decided that I might just do a version of what was originally at the top of the firewall. Don't have a die set that big but this will do fine. Will have the reverse though with it sitting out rather than in. The blue french curve I picked up in an art shop in Prague last year of all places! Just laid it in the original bead and did a quick transfer onto some scrap to see how it would look.
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