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  #817  
Old 03-01-2015, 08:54 AM
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Re: Grand Willys project

Sorry to hear about your back. Thanks for posting the picture. Get well soon.

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  #818  
Old 03-14-2015, 07:20 AM
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Re: Grand Willys project

Not much to show as days were spent finessing the panels while areas were still accessible.


Had a lot of work getting this part of the cowl to match the other side and be even. Above the louvres was concave and then became convex in the middle and flat at the bottom! So I started by hammering out the convex area and reduce the crown some in the middle so it transitioned to the flat along the bottom nicely.


On the side that had too much crown in the middle, I marked the high areas with chalk and then use this crowned hammer to hit in the middle of the skate wheel held on the inside. This shrunk the panel down without an causing oil can.


On the low crown side I use this round dolly and pushed outwards with it hard from the inside while tapping around it lightly from the outside. This raised the crown and got rid of the oil can that the other side had as well.


I couldn't find a hammer like this at the last swap meet to buy so I modified another I got. Extended the head and then welded on a ball bearing.


Another view. Works well for raising small low spots


After tacking the cowl together while clamped to the firewall, I took it off and tig welded it together for the first time. Then laid it over like this so I could planish the weld.


Took many hours over several days but finally got it flowing nicely I think.


When widening a curve like this you have to rework the whole radius from one end to the other.


I doubled the amount of plug welds over the original spot weld count as they were pretty spaced out. Like to keep them around 2" apart.


Had to rework the area where it will join onto the windscreen too. Hope it all works out in the end.
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  #819  
Old 03-15-2015, 09:43 AM
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Re: Grand Willys project

Humbly speaking for the vast majority of us who will never attempt a project of this magnitude, thank you so much for allowing us to vicariously participate in your build. I, for one, am more amazed at your craftsmanship and attention to detail with each subsequent post. I'd be embarrassed for people to know how many times a day I check to see if you've posted an update , but it's always a good day when you do post. Thanks again.
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  #820  
Old 03-17-2015, 05:51 AM
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Re: Grand Willys project

Quote:
Originally Posted by sonofasailor3 View Post
Humbly speaking for the vast majority of us who will never attempt a project of this magnitude, thank you so much for allowing us to vicariously participate in your build. I, for one, am more amazed at your craftsmanship and attention to detail with each subsequent post. I'd be embarrassed for people to know how many times a day I check to see if you've posted an update , but it's always a good day when you do post. Thanks again.
That is good to hear.
Always had it in my mind since an early age that I wanted to do a ground up build like this for some reason? Never knew I would get the opportunity though. Learning so much and getting to know people that have taken the time to take an interest from all over the world is certainly something I didn't think of so long ago. Amazing how this can be shared so easily now a days.
I still think back to when I started my web site and would have to wait until a roll of film was full before I could do a write up. And then have to hope they all turned out as there was a long wait if you had to re-take any shots!
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  #821  
Old 03-21-2015, 08:29 AM
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Re: Grand Willys project

Was not sure if to add this to the thread or not but might be the last post for a while as going to tackle floor tiling for the first time after ripping up all the carpet today in the house, apart from the gym.


Picked up this 1920's cast iron seat from a horse drawn cultivator at the Ballarat swap meet.


I had given it a clean with a wire brush and showed no cracks.


Didn't have my citric acid bath setup so thought I would use the old molasses technique of removing rust.


I had actually bought this jar to put on my toast like I used to some times as a kid. Didn't like it at all now so might as well make some use from it.


It was only a 500 gram jar so was not going to get much solution from it as most do a 10 to 1 ratio with water with it. This meant only 5 litres of hot water could be added but was not enough to cover it. I threw in a couple of litres of white vinegar with it but still ended up with about a 20 to 1 ratio with extra water I needed. I even displaced as much as I could by filling any space with bricks.


You can see the reaction that happens with it and this was after about 1 week. At about this time it goes from smelling slightly sweet to unpleasant!


Being a weak solution I thought I would check it after 2 weeks of soaking.


Hit with a high pressure sprayer.


Looks like it is good enough to paint now. I dried it with compressed air and then a blow torch and had to be really quick to coat it with primer to seal it all.


Now to make it into a stool. For a base I pulled another of my old Jeep wheels out from under the house.


After a though scrubbing and wire brushing, I welded a piece of tubing to the base from both sides. The top I reduced for the fitting I had for it.


Bent some plate to suit the base of the seat and welded it onto an old office chair height adjuster.


As the tubing was zinc coated, I hit it all with some etch primer.


Drilled out the centre of the hub cap and made a plate to hold some wheel studs in from behind so I could fit some wheel nuts as well.


Can get enough adjustment to suit what I do with it.


All done and more comfortable than it looks. The top of the wheel make a great foot rest and why I left the wheel complete rather than just using the centre.
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  #822  
Old 03-21-2015, 11:48 AM
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Re: Grand Willys project

Well done! Great craftsmanship, idk how you do it


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  #823  
Old 04-14-2015, 06:02 PM
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Re: Grand Willys project

Nice stool. Now stop cocking around with the tiling as I need a 'fix' of your workmanship. Lol


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  #824  
Old 04-15-2015, 05:29 AM
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Re: Grand Willys project

Quote:
Originally Posted by UKWK View Post
Nice stool. Now stop cocking around with the tiling as I need a 'fix' of your workmanship. Lol


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Believe me, I'd rather be out in the workshop working on it any day!
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  #825  
Old 05-04-2015, 08:57 PM
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Re: Grand Willys project

Tiling all done and very happy with the results.
Just a little update to get back into it.


Funny how something can suddenly annoy you. The top of the lower pressing, where it runs into the cowl section, pulls in as it is not wide enough there.


I could have just had some body filler applied over it, but it would be better done right if possible.


Hard to see but I cut horizontally just below the top fold using a 1mm cutoff disc.


I was was careful to pull it outwards without levering off the cowl as would have bent it in. Only had to move it less than 3mm-1/8".


After tacking to hold its position, I did what I call tack stacking to fill the gap. I didn't jump all over the place but started at one end went right through to the other by placing a tack, and then just before it looses its orange colour, quickly tack again, half still on the last tack. This leaves enough time to stop blow through from being too hot and you get better fusion to the last tack than you would if cold. No pin holes this way. Can see it left a even HAZ, (heat effected zone), which is important for controlling distortion. No hammer work was needed afterwards.


Used a 7" flap wheel to clean off the weld and works quite well. Had not used it before and less likely to leave dips.


Think it flows better now. Both sides were done the same.
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  #826  
Old 05-05-2015, 06:13 PM
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As always. Great craftsmanship!
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  #827  
Old 05-09-2015, 06:53 AM
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Re: Grand Willys project

A little bit more done. They all add up though.


The ends of the sill supports had rusted so I just folded some card over the end to get a pattern.


Here is a part of the section that is being replaced.


The citric acid cleaned it up nicely, but can't replace the lost metal.


New section made and fitted.


The other end of the support also had some rust but was also the wrong profile. The donor floor is flat longer than the original, so this needs to be changed.


New piece made.


Also had to extend the length of the sill supports to match the longer cab. As the support is curved on one side, I added the length at the widest point.


For some reason the sill support flange that fits under the sill was not spot welded to the sill like it was on the earlier cab? Not sure if a change of company policy or just a slack assembly worker? I have drilled holes ready to plug weld it together for the extra strength it gives.


The end of the sill that braces the bottom of the A pillar was also missing any welds. So I will be adding those too.




I decided to add the sill supports before the floor extension so I could get more welds done inside where it meets both pillars. I could then also re-coat the inside of the sill.
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  #828  
Old 05-09-2015, 06:54 AM
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Re: Grand Willys project

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Originally Posted by Sleeps View Post
As always. Great craftsmanship!
Thanks mate.
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