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  #865  
Old 07-04-2015, 07:57 AM
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Re: Grand Willys project

Things have slowed down due to a right shoulder injury, but still have a bit to show with what I could do left handed.


If you look closely you can see some of the damage that needs to be taken out. From the dent in the middle of the side to the corner in the left of the picture where the circular crease is, it has all be flattened inwards. This also continues along about 2/3rds of the way from the same corner the other way too. Every side has similar damage all the way around.


Got all the major dents out and back into shape again.


Doing some final dressing using a lead bossing stick. This and another one was given to me by a old plumber and can still be bought today under lead working tools. I used the hand beater bag on the outside and worked out any remaining high spots and shape that was needed from the inside.


All the flat areas, dents and creases are pretty well gone now.


They were all along the front face too.


Now to divide it into 4 equal pieces


Wasn't sure how to get nice straight lines when dealing with the surface being a compound curve. So set the roof up vertically and level in both directions and used a cheap laser level to get my lines.


Then cut it into 4 with a jigsaw ready to go into the citrus bath later on to rid it of any remaining rust. Will be mainly using only the perimeter of the these pieces and a whole new centre part of the roof will be welded in to make it longer and wider to suit the bigger cab.

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  #866  
Old 07-04-2015, 10:05 AM
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Re: Grand Willys project

I hope the shoulder improves soon. As always, the work is amazing. I especially like the pictures of your two furry, four-legged supervisory team members.
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  #867  
Old 07-05-2015, 06:10 AM
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Re: Grand Willys project

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Originally Posted by sonofasailor3 View Post
I hope the shoulder improves soon. As always, the work is amazing. I especially like the pictures of your two furry, four-legged supervisory team members.
Thanks mate, they are telling me to come inside!
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  #868  
Old 07-18-2015, 08:44 AM
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Re: Grand Willys project

Bonnet time!

I have this spare bonnet, as well as the grille, from a 1952 Willys Wagon that came with the 58 Truck when I bought it. I think it was deemed too hard to repair as it has bowed down across the middle of the bonnet a good 16 mm- 5/8", from someone walking on it. Most of the damage it right through the two vertical sides of pressings.


Something had also pushed up in under the front support as well causing a bulge on one side near the same pressing line.


So took out the support to get full access to the damage and will remove the rear one as well.


Really hard to show but you might be able to see the big gap under the ruler edge that you can easily fit you fingers underneath in the middle of the bow.


I worked up the creases and dents along the pressing and is looking a lot better, but still not good enough. You might spot also the middle of the bonnet also still sags down.


Time to get creative. If walking around on put the bow in, it should get it out! Supported the front with my small beater bag and gently pressed down on the worse spot. Wore sneakers rather than my steel capped boots to get more feel and less hard edges. Would do a bit and then check with the straight edge noting where more was still needed.


Just about there now and a few shrinks with the shrinking disc should get the last millimeter.


For the middle I placed a block against the side of the house and tilted the bonnet until it was only just being held against the block. While holding the top and ran my foot right down the middle with even pressure and it came out rather well. I put these techniques under 'primitive but effective'!


On to the 58 bonnet now. I stripped out the supports ready to take the dents out of this one. Noticed this later one the that it had more spot welds on inner edges of both supports which seems strange as that is usually not done.


These has dents all over it and these ones near the front as well. Two to the left of the trestle and one to the right of the pressing line.


Once I have the dents out I will decide which pieces to use from each bonnet. This needs to be made 220 mm-9" wider over all. It is not just a matter of adding a section from the other one up the middle as the centre higher part sits over the grille and this is only going to be 120 mm-5" wider by adding 2 extra grille slots. The other 100 mm-4" are over the headlight area, 50 mm-2" each side, which is the lower part of the sides.


To make the other bonnet wider on both sides of the pressings, I would cut the pressing area out of one and then add sections back in, like what has been cleaned of paint on this one, with the extra required width. Still means four long welds that I have to get perfectly flat and distortion free, but any other way would mean 6 or 8 welds! Another section also has to be added across part of the back of the bonnet when the centre part comes forward. I found that hard to explain so hope it makes sense?
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  #869  
Old 07-18-2015, 01:54 PM
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Re: Grand Willys project

Wow. That is going to be a cracking truck when done.
Thanks for all the explanations and photos.


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  #870  
Old 07-18-2015, 03:13 PM
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Re: Grand Willys project

Thanks for the latest update. I was beginning to go through withdrawal symptoms!
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  #871  
Old 07-19-2015, 06:57 AM
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Re: Grand Willys project

Glad you understood my mumbo jumbo as wrote that last explanation 4 times!
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  #872  
Old 07-19-2015, 11:42 AM
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Re: Grand Willys project

Marcus, what are your plans for the dash? Are you going to adapt GC dash or restomod the Willys's?
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  #873  
Old 07-19-2015, 11:02 PM
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Re: Grand Willys project

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Originally Posted by sonofasailor3 View Post
Marcus, what are your plans for the dash? Are you going to adapt GC dash or restomod the Willys's?
Going to try first to use the Grands dash as the rear of the interoir will be from that too. Going for the old outside new inside theme without clashes of having both in the same space. It wont be any where near as deep though as measuring it, looks like only from the back of the top air vents forward will be used. Going to be tight getting the back of the instrument surround in.
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  #874  
Old 07-19-2015, 11:03 PM
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Re: Grand Willys project


While my shoulder is healing, I have to take a 10 minute break after every 30 minutes of stripping the paint. So was a good time to try a mock up of the cab pieces.


Looks way shorter than the 2" section taken out above the belt line! Looks more like the current model Wranglers roof line.


Looks a lot different now with the original roof panels in place. Always thought they looked a bit too tall in the roof and now even worse with the sectioning.


I always planned to 'pancake' the roof but wanted to make sure it was really needed first.


The left roof panel is from the front and is 45 mm-1"3/4 lower than the back panel on the right.


I quite like this height, or something in between, so might do a combination of taking an inch off at the bottom along with the flange where it is spot welded into the gutter. Then refold the flange into the edge. I don't think I will take the same amount out of the front though but reduce the wedge shape by maybe an inch front to rear.
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  #875  
Old 07-23-2015, 11:24 PM
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Re: Grand Willys project

I've been following this build since I joined a few short months ago. Absolutely a labor of love and true craftsmanship at work here.

Keep up the amazing work, what's the timetable look like?
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  #876  
Old 07-24-2015, 06:05 AM
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Re: Grand Willys project

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Originally Posted by farfromovin View Post
I've been following this build since I joined a few short months ago. Absolutely a labor of love and true craftsmanship at work here.

Keep up the amazing work, what's the timetable look like?
Thanks.

Always saw this as a 10 year project and about halfway through it now now time wise. Doing a lot of other jobs including house renovations in that time so might have more time on my hands now.
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