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  #853  
Old 06-13-2015, 08:36 AM
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Re: Grand Willys project

Getting close to finishing off the lower part of the cab for now.


I had a good pair of original Willys front cab mounts that were rust free after cleaning them up in the citric acid bath. Hoping to use them on the donor firewall.


But the fold on the donor firewall sits a lot lower than it was on the Willys. That rear brace support is supposed to touching the floor showing how low the whole mount is.


The angle is different as the Willys had two 45* bends in the toe board to firewall where the donor has three 33* ones.


Looked at modifying the originals a lot to fit but thought it would be better just to start from scratch. First need to workout how far back I need to go to get the bottom of the mount level with the bottom of the floor while still being behind that lip.


You might noticed too that the second fold is down on an angle. That is because the donor firewall is not flat straight across like the Willys was. I wanted the lower part to still be like that. I had to continue down the firewall until the lower part was vertical and square


Time to start converting cardboard into metal. I made it out of 3 mm instead of the original 2 mm so the extra stiffener on the outside edge could be left out.


The main stiffener which transfers the load to the stronger side of the cowl was still put in.


With the body mount sitting back it gives more room in the engine bay, but more importantly, centers the load under the firewall which is much stronger than in front of it.


Had another set of original floor to mount braces and thought I might as well reuse those.


The radius just needs to be tightened up in the corner to match the new mount.


Used a T dolly that I had made a while ago that had the same radius.


Hammered the brace over it and now it is ready to be welded on.

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  #854  
Old 06-13-2015, 01:59 PM
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Re: Grand Willys project

Outstanding. Thanks for my weekly fill.


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  #855  
Old 06-14-2015, 06:22 AM
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Re: Grand Willys project

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Originally Posted by UKWK View Post
Outstanding. Thanks for my weekly fill.


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A pleasure.
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  #856  
Old 06-14-2015, 11:53 AM
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Re: Grand Willys project

I sat down the other week and read through this whole thread. Your build is on an entirely different level.

It is awesome to see the updates every time a look. Cannot wait to see a finished product.
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  #857  
Old 06-15-2015, 06:57 AM
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Re: Grand Willys project

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Originally Posted by CNY_WK2 View Post
I sat down the other week and read through this whole thread. Your build is on an entirely different level.

It is awesome to see the updates every time a look. Cannot wait to see a finished product.
Glad to hear it was worth reading all the way through.
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  #858  
Old 06-20-2015, 08:58 AM
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Re: Grand Willys project


Made the mount for the other side before welding on the first one. This way I can make sure they are perfectly level as can adjust them in opposite directions a few millimeters each if needed. I did a total of 23 plug welds to attach each one to the floor, firewall and cowl sides. The cowl sides were already double thickness so increased the plug weld holes from 5.5 mm, (7/32), to 8 mm, (5/16), to get the needed penetration.


I have run sealant around all the joints to keep water out after coating with zinc. Will top coat this with edge primer and that should take care of it until the cab is finished.


Just want to show a little trick to fill this join groove neatly with sealant.


I place masking tape on each side.


Run the sealant into the groove and then smooth it with a small spatula. I kept it moist with water as it is an acrylic, but silicons etc, I dip it in mineral turps or whatever they recommend for clean up. Try a scraping down until the tape edges show.


Quickly pull the tape before it dries. I get best results pulling back flat and away from the sealant.


Actually quicker this way as no clean up and looks better. Not that it really matter in this case, but no harm in practicing a good technique.


So that is the lower half done for now. I have shortened my trestle at the front so that it could be tack welded directly to the mounts. The rear is also on the mounts and is not supported anywhere else. I feel this gives me the best chance of simulating its position once it is bolted to the chassis and so door gaps etc stay the same. Will also allow me to bolt on the front guards too when the time comes.
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  #859  
Old 06-20-2015, 12:15 PM
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Re: Grand Willys project

Still following this truly amazing journey,Marcus. How's your back holding up?
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  #860  
Old 06-21-2015, 05:40 AM
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Re: Grand Willys project

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Originally Posted by cheapjeep View Post
Still following this truly amazing journey,Marcus. How's your back holding up?
Thanks for remembering and asking. It's has been behaving itself quite well of late.
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  #861  
Old 06-26-2015, 05:37 AM
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Re: Grand Willys project

Just a quick round down on the cab so far.

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  #862  
Old 06-27-2015, 08:12 AM
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Re: Grand Willys project


A start has been made for the upper section of the cab. Using a 7" stripping disc I have had to go through 7 layers including primers and a skim coat of filler some where in the middle. Grey originally and been repainted into cream twice. I felt like an archaeologist! Grey primer, grey top coat, red oxide primer, cream top coat, filler skim coat, grey primer, cream top coat.


No surprises were found and very little rust pitting, but a heap of dents and flat spots. Looks like it had been stood on a number of times and caved in before being popped up again.


Underside not too bad with some surface rust showing through.


Only 4 layers of paint on the underside so literary took half the time to strip. 2 hours for the topside and 1 hour for the underside. Took one whole strip disc to do it all.


The long flat areas I took out mainly with the bigger mallet hammering into the hand sized sand bag. At no time was a metal hammer on metal dolly used directly as don't want to stretch the metal at all. The rubber dollies with lead inside came in handy for this too. The photo is from before I started.
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  #863  
Old 06-27-2015, 11:15 AM
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Re: Grand Willys project

Thanks for the update, Marcus. It looks like it went be too long before the cab is together.
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  #864  
Old 06-28-2015, 06:00 AM
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Re: Grand Willys project

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Originally Posted by sonofasailor3 View Post
Thanks for the update, Marcus. It looks like it went be too long before the cab is together.
Be a while yet as will be stripping paint off all remaining parts ready for a soak in the citric acid bath. It is only good for around 3 months so might as well get everything ready to go through it within that time.
Also be off to Europe again soon so will set it up when I get back.
I have to strip and dip 2 hoods, 2 grilles, 2 roofs, 4 doors, front fenders, pair of rear fenders, tailgate, splash apron etc to do!
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