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  #829  
Old 05-10-2015, 02:41 PM
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Re: Grand Willys project

Brill. Thanks for the pictures and explanations. Learning loads.


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  #830  
Old 05-11-2015, 05:19 AM
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Re: Grand Willys project

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Originally Posted by UKWK View Post
Brill. Thanks for the pictures and explanations. Learning loads.


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Thanks mate. Heading over to the UK for a month in a few months time. Is there any where that sells Jeep branded stuff, clothes, watches etc, at all? I have bought a bit over the years off eBay from the UK but don't know where it was originally sold?
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  #831  
Old 05-11-2015, 01:33 PM
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Re: Grand Willys project

I think most comes from the Dealers and the rest from the states.
If you want I can always act as a collection point and get the stuff to you in bulk or when you come over.
I've sold my 07 Grand Cherokee Overland and gone back to a thoroughly British 4x4.

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  #832  
Old 05-12-2015, 06:42 AM
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Re: Grand Willys project

Quote:
Originally Posted by UKWK View Post
I think most comes from the Dealers and the rest from the states.
If you want I can always act as a collection point and get the stuff to you in bulk or when you come over.
I've sold my 07 Grand Cherokee Overland and gone back to a thoroughly British 4x4.

Attachment 56030


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Thanks for the info. Thought you might have had the dedicated Jeep stores like we do here and in South Africa.
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  #833  
Old 05-12-2015, 05:10 PM
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Re: Grand Willys project

Not a big enough market share for that. Definite minority vehicles in the UK. Maybe one of the specialist parts importers might have some stuff.


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  #834  
Old 05-14-2015, 07:09 AM
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Re: Grand Willys project

Tiny market here too but even non Jeep owners are buying it.
Quite nice stuff too.
Jeep Apparel | jeepapparel
I have a heap that I bought on my Jeepaholics FB page.
https://www.facebook.com/Jeepaholics
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  #835  
Old 05-16-2015, 09:20 AM
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Re: Grand Willys project


Time to finally fill in the floor. Just cut a quick cardboard template.


Added extra for the folds and a stepped flange to go under the donor floor.


Found this LED light handy for following the line. Just sold in Bunnings as a barbeque light! They have a strong magnetic base or you can use the clamp.


I will roll in a step flange along the edge where it tucks under the donor floor. There was already the same setup on this edge as this was where the donor door sill attached. Shows just how wide the Willys cabin has become.


Using the bead roller I tipped the edge so it can be plug welded to the cowl stiffener. Used a shrinker to make the bends in the flange.


Tipping the edge of the floor over the door sill to give it extra strength. It has a slight curve all the way along so could not use a folder.


Had to straighten out the floor after tipping the edge due to the curve. I find it easier to hold a ruler along it while using the shrinker/stretcher so I know precisely where and how much to move it. The shrinker will bring it towards to the ruler and vice versa.


Used my old home made back gauge to mark where to trim off the excess.


And it didn't fit! It is out by the material thickness so wont sit down over the top of the sill. I had marked it with the panel sitting on the sill, but the pencil was on a bit of an angle and I didn't allow quite enough for that.


To move the fold I placed it on the edge of my table that I have radiused the edge of. As the radius was a bit bigger than that of the fold, I could hit down with glancing blows with a nylon headed hammer to move the fold. I use the nylon head so it does not thin and stretch the metal while doing it or leave many marks.


Now it fits perfectly. Next the panel will be coated in zinc primer where it tucks under the donor floor and also right along the underside.


Plenty of plug welds are needed. The two rows at the front connect the sill support to the sill itself. This turns the sill channel into a boxed member adding much strength to it all. The plug welds along the donor floor were done where the holes already were from drilling out the original spot welds. Fully welded the floor to the A an B pillars as well just like the factory did for extra support.


I could have only sanded the front row of plug welds as the rest will end up under the carpet, but you know what I am like.


More zinc primer down and later will fully seam seal the joint top and bottom.
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  #836  
Old 05-19-2015, 01:15 PM
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Re: Grand Willys project

I am continually amazed by your craftsmanship. After following your progress for so long, it is beginning to look like there might be a light at the end of the tunnel. I've enjoyed the journey with you, and while I'm excited to see the remaining work to the end, part of me wishes you weren't so far along in the build. Extraordinary work and attention to details. Thanks for sharing
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  #837  
Old 05-21-2015, 05:43 AM
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Re: Grand Willys project

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Originally Posted by sonofasailor3 View Post
I am continually amazed by your craftsmanship. After following your progress for so long, it is beginning to look like there might be a light at the end of the tunnel. I've enjoyed the journey with you, and while I'm excited to see the remaining work to the end, part of me wishes you weren't so far along in the build. Extraordinary work and attention to details. Thanks for sharing
Thanks for taking the time to comment. Glad it is still of interest after such a long time.
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  #838  
Old 05-23-2015, 08:54 AM
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Re: Grand Willys project


Need some floor supports that go from the bottom of the A pillars across to the transmission tunnel. I had a good pair of stock ones but they were too short and made for the original floor pan which is on an angle there. Also had saved some ends from the donor, but decided in the end that it would be better to make new ones from scratch.


Folded up some hat channel to start with.


Cut a T at one of the ends and placed it on the corner of the bench ready to flatten out the fold.


Knocked out the fold ready to make the wider end that braces against the bottom of the A pillar and floor support.


Cut some shape into it like the original ones.



Bent the cover piece over a solid bar with the nylon mallet.



Tacked in ready for welding.


Now I had to clear the flange where the new section of floor joins to the donor floor. Rather than just cutting the flange away I thought I would press the clearance in


With the longer piece taped underneath I placed another couple of pieces of scrap each side of it on top. Then taped them as well.


Put it all in the vice and did it up nice and hard. Gave it a hit with a bolster until it left a mark in the tape right across showing I had the depth I needed. Raised it up a bit and it it again with the bolster to get the outer edge done as well.


Shows how I clear the metal now.


Did the end bits as well to clear the flanges on the floor supports. The factory just cut it instead but thought might as well do it this way to get a better seal and stronger too.


Holding it up you can see how it clears both flanges now. I actually shorten the hump a bit before welding it in.


Now for the other end. To terminate it like stock it needs to go up inside the tunnel a bit. This reduces any stress rises. Just marked the flange where it last touched the floor and then cut to that point. Bent the flange around the corner. Placed a straight edge on the tunnel down past the end of the support to get the angle and how much to cut off for the rest of it.


Made an end piece after putting a bit of radius at the top. Can see the stock one next to it that I am getting my ideas from.


Welded up and ready for fitment.


I zinc coated just the inside of the support. I drilled the holes through the floor rather than the flanges as get better welds than doing it over head from the underside. I cleaned the coating off at the weld points, even though it is a weld through coating. Less chance of any porosity and going to burn off anyway this close to the weld.


Was getting late and the dog came to let me know! wink emoticon Some weld penetrates right through from the top leaving little mounds.
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  #839  
Old 05-27-2015, 04:29 PM
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Re: Grand Willys project

Outstanding. You know, it just encourages me to try harder and do better when building anything now. Just watching this come together is a real pleasure.
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  #840  
Old 05-27-2015, 05:54 PM
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Re: Grand Willys project

To say how much i enjoy reading and sharing your build journey is simply an understatement

True craftsman

I think jeep should fly you to Detroit to give some lessons to those on the production line about quality and attention to detail, as well as some training to engeniers


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