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  #793  
Old 01-18-2015, 04:30 AM
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Re: Grand Willys project

Love them French curves. 😏


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  #794  
Old 01-19-2015, 03:20 AM
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Re: Grand Willys project

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Originally Posted by UKWK View Post
Love them French curves. 😏


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Ha ha.
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  #795  
Old 01-19-2015, 05:02 AM
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Re: Grand Willys project


I tigged a flange on the end of the firewall now I had the exact angle and position of the cowl worked out.


Put a joggle in to go over the inner reinforcement panel of the cowl using a step die in the bead roller.


The cowl will be plug welded to this flange similar to the original spot welds it had before.


From the inside you can see how the edge of the firewall and the inside of the cowl come together. The joggle I showed in the flange is to go over the inner panel of the cowl.


Also folded up some 7" long sill extensions to fill the gap in the longer cab. Will weld them to the back section once the cowl and firewall etc are completed so they can be welded and planished easier.


I need to extend the floor out to the sill as the donor floor was not wide enough to suit the wedge shape of the Willys cab after the widening. Normally I like to butt weld everything but thinking I might run the metal through my step die and plug weld it in the old spot weld holes.


The floor panel would end up flush. The donor floor is all galvanized so would make tigging hard anyway. Also would have to weld closed every one of those old spot weld holes if butt welding it.


This is the gap I need to fill. The old floor went over the top of the sill and folded down the first step. Might do the same.


Can see a lap joint along the edge will not exactly look out of place under there. Would coat the joint before welding with zinc and also seam seal it afterwards top and bottom.
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  #796  
Old 01-19-2015, 06:07 PM
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Re: Grand Willys project


This is a bonnet off a FJ45 Toyota Landcruiser. Wanting to use the louvers from it. Looks like they liked the Willys Wagons and Trucks which predate the first Landcruiser by 5 years. Even the hinges are in the exact same spot. Works in my favour.


Was surprised to see there was a difference in the louvers for the heater intake from the same model! Wonder why Toyota had the two different designs on the same vehicle? The bonnet ones have a rounded back edge rather than angled.


Maybe it is a different shape because it opens up more? I would really prefer them to match but not sure where I can get 6" long louvers to match the bonnet ones?


Damage needs to be looked at to make sure this is usable. Was one of the reasons the bonnet was discarded, but I was happy to give it a go to repair it.


Underside shows the damage from a different angle.


Cut a block of timber to match the curve of the Willys bonnet in the same area as the louvers will go.


Can see how much the louvers need to come down to match the curve of the block.


Used a bolster to hammer over the block to bring the back edge of the louver down to the right shape. Only hammered on the flat strip between each louver.


That has improved it quite a bit already.


Back side shows how far it has come.


To repair the crease in the louvers and bring the front up, I just quickly shaped some timber to match.


Use this hammer to raise the crease and the front of the louver over the timber stake.


Looks a lot better. In fact I have to work on the 'undamaged' side now to make it as even!
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  #797  
Old 01-19-2015, 06:15 PM
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Re: Grand Willys project

My good you have some skills
Where have these skills gone in the panel shops today
If they can't just bolt on a new part they throw the whole thing away.


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  #798  
Old 01-20-2015, 02:52 AM
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Re: Grand Willys project

Quote:
Originally Posted by fwdjeep View Post
My good you have some skills
Where have these skills gone in the panel shops today
If they can't just bolt on a new part they throw the whole thing away.


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It is a dying art for sure in mainstream repair. Labour too expensive now.
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  #799  
Old 01-24-2015, 06:24 AM
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Re: Grand Willys project

Getting a bit carried away with the pictures at the moment so hope you don't mind. Tend to do that when covering something new for the first time.

Just thought I would show a mock up of how I make a 'fair' curve. Just use a thick stainless ruler and place magnets to hold the curve I am after that intersects a start and finish mark as well as the depth of the curve I want.


So here is my first use of the bead roller. It is a reversed version of what was there on the original firewall. The two vertical ends match up with where the hinges will go on top of the cowl to give extra strength.


Want to tidy up the ends of the bead. Picked up this trick from one of the forums where you just notch out a piece of pipe where its ID matches the OD of the bead


Just placed it on the table and gave it a hit and much neater now. Tried it over some rubber as well but straight on the bench gave the best result.


Had to raise where the bead had been run over in the other direction. Clamped a curved hammer face in the vice and used a small soft headed mallet to get the crease out.


I tried a square outside corner first using some notched SHS, but decided on the same tube trick with only a 1/4 left to curve the bottom corner.


Now to use the tipping wheel for the first time. Tightened in down into the wheel about 3 turns.


First pass I just guided the wheel through to mark the line and start the bending.


Next pass I lifted up on the side of the piece as it passed through increasing the bend.


Third pass.


Forth pass and is far as I can go. It is touching the bolt head as well as the side of the washer. An extra turn can give a little more but was close enough to hammer and dolly the last bit.


Use a small soft mallet and steel dolly to tip the last bit.


The tight corner as caused it to bend. The outside edge needs to be shrunk to get it straight


Just used a shrinker to get it straight at the ends. Can see the cheap soft mallet I used for the tipping and other tools for correcting it until perfectly flat.


Bottom edge was tipped and needed very liitle work afterwards. Only the bottom corners where I couldn't get all the way to the end with the tipping wheel


I needed to make an extra curved tip to the flange in the middle of the bottom section. Found some scrap under the house and quickly made these T dollies in different diameter rods.


One fitted perfectly the curve I needed. This lip turns up to give clearance to the back of the engine cover.


The first part had to stay flat and then the curve was needed. Used a soft mallet as didn't want to stretch it while bending it over.


Fits in quite nice.


Just dropped in place without clamps. Only a slight gap at one end which I corrected later. Was only the bit done by hand and must have missed the mark when bending it with pliers.


Cowl sides and top tested to make sure it all goes together. Better than expected but I did remember to take off the material thickness twice when adding on the flange width to the template.
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  #800  
Old 01-28-2015, 08:34 PM
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Re: Grand Willys project

Spent the better half of the last week reading 4 years worth of building. Absolutely amazing craftsmanship. Props to you sir. I look forward to seeing the rest of this build.
I personally think you should do a green color, Jeeps are supposed to be green.
P.S. The more pictures the merrier, I wouldn't mind seeing 20 pictures per update.
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  #801  
Old 01-30-2015, 03:00 AM
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Re: Grand Willys project

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Originally Posted by 07Limited View Post
Spent the better half of the last week reading 4 years worth of building. Absolutely amazing craftsmanship. Props to you sir. I look forward to seeing the rest of this build.
I personally think you should do a green color, Jeeps are supposed to be green.
P.S. The more pictures the merrier, I wouldn't mind seeing 20 pictures per update.
We are leaning more towards a green lately actually. A dark olive colour.

You will have to go back through again soon as I will replace all the missing photos that FB changed the addresses on! Lost all of last years work and some in the beginning.
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  #802  
Old 01-31-2015, 12:10 AM
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Re: Grand Willys project

I noticed most of the last year was missing, but your write ups are great. I can understand what's going on just from the text.

I'm glad your leaning to the green. I may be a bit partial to the green since my jeep is green haha
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  #803  
Old 01-31-2015, 01:02 AM
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Quote:
Originally Posted by Gojeep View Post

We are leaning more towards a green lately actually. A dark olive colour.

You will have to go back through again soon as I will replace all the missing photos that FB changed the addresses on! Lost all of last years work and some in the beginning.
Shhh stop posting without more updates!.. getting my hopes all high just to be crushed.

But really great work as always. The jeep is already a work of art and it only gets better as you work on it. Im just sad that i will probably never see it in person.
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  #804  
Old 01-31-2015, 02:30 AM
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Re: Grand Willys project

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Originally Posted by Sleeps View Post
Shhh stop posting without more updates!.. getting my hopes all high just to be crushed.

But really great work as always. The jeep is already a work of art and it only gets better as you work on it. Im just sad that i will probably never see it in person.
Haha that's how I felt when I got an email saying GOJEEP replied. I'm was looking forward to an update, but a reply is good with me.

I want to see this build in person also, and unfortunately I will probably never see it in person either sleeps
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