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  #877  
Old 08-01-2015, 08:38 AM
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Re: Grand Willys project


Took the dents out and welded up holes etc from the 58 bonnet. I will only be using the piece each side of the centre one to make the other bonnet wider. Wanted to make those pieces a bit wider up to the centre ridge, but the leading edge had rust holes right through in that area.


Also started preparing the FJ45 Landcruiser bonnet vents so I could use them. I wanted more flat area next to the louvers so needed that step up part gone.


Put them in my English Wheel to flatten the two folds.


Can see it getting less within a minute of work.


Took more time to setup the photos than to flatten it!


This is how it came out without any further sanding etc. Straight from the wheel.


Got to see how it fitted the 52 Willys bonnet for the first time. Great to see it matched the contours and thought everything was sweet. But then I noticed the lower part of the louvers were going up hill and that they were not parallel with the end of the bonnet either. Might be able to see the scribe line as see how much it was out.


The top edge of the louvers actually matched the fold in the Willys bonnet exactly. On the Landcruiser though it tapered away from both the fold and the bottom edge as the louvers get smaller towards the front.


If I made the louvers parallel with the back edge of the bonnet, it hung out like this. It is very hard to bend the louvers to correct this as you are basically bending angle iron for each one.


I started forcing the louver into the new bend over my knee and was able to clamp it into place to see what it looked like. The taper is now the same distance from the bottom of the bonnet as it is from the fold and looks balanced the same is it is on the Landcruiser.


Took several hours off carefully bending the louver over a pipe in the end to get it all even. But the top would tip downwards where the bending was taking place so had to stretch that area of each louver to get it back up while not doing that to the base of each one.


Can see I had to shrink around the base as well as it wanted to sit up compared the the front of the piece. Least it was easy to see if each and every louver was touching the bonnet by looking through them.


Sitting without any force now so time to do the other side. I also had the bonnet support clamped in the whole time to make sure I had the final contour in place to shape to.

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  #878  
Old 08-01-2015, 09:36 AM
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Re: Grand Willys project

Thanks for taking the time to document it. You could easily get carried away and miss something.


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  #879  
Old 08-02-2015, 07:13 AM
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Re: Grand Willys project

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Originally Posted by UKWK View Post
Thanks for taking the time to document it. You could easily get carried away and miss something.


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I do sometimes but it helps that I had to do most things for both sides. I had already done one side of wheeling the fold out next to the louvers and thought that might be worth sharing. So went inside and grabbed the camera before doing the other side.


Both sides done now.


Bit of an overview. Spacing from the rear edge I have made the same as the FJ45 they came off.


Pre 1972 Landcruisers actually had the vents more around the side like this. Looks like gills on a shark!


Thought about doing it this way but then realized the hot engine air would then be drawn straight into the louvers I made in the side of the cowl for the AC intake.


Function over form so they will go on top. No turning back now.


Got some good fit up ready to be tigged.


Tacked in place. I grind down the tacks before welding right over the top of them again with the tig.


I weld without stopping as far as I can go. Did have a problem along the bottom where I lost sight of the join as it was so tight! So had to double up in the area.


Hammer on dolly right along the weld area until it was perfectly straight with a metal ruler against it.


This was the same vent that was badly damaged if you remember and that I repaired.



The very same vent as above so was worth fixing.
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  #880  
Old 08-02-2015, 11:40 AM
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Re: Grand Willys project

Lovely job. Beer time.


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  #881  
Old 08-04-2015, 06:02 AM
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Re: Grand Willys project

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Originally Posted by UKWK View Post
Lovely job. Beer time.


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Ha ha, more likely cider or Baileys time.
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  #882  
Old 08-05-2015, 05:41 AM
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Re: Grand Willys project

Hope no one minds a mid week update.


Second set of louvers in.


Back view.


Just get it all nice and straight and then do this!


Cut the step up part out that separates the higher grille slot area from the sides over the headlights.


Here you can see the two parts cut from the other bonnet inserted. These have been left much wider than I need as want some extra to make sure the hinges don't end up right in the middle of a weld seam. Also allows me to adjust the centre section width exactly after the extra grille slots have been added. New wider side pieces where the headlights are will be made for the grille later too.


An extra panel will have to be made up at the bottom of the centre section. Will have the same flattened fold at the end to give some stiffness. All this will go into the citric acid bath to get rid of any rust left. Will weld it all together after that.
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  #883  
Old 08-19-2015, 02:30 PM
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Re: Grand Willys project

Getting withdrawal symptoms. Could we at least have a photo of the acid bath. Lol


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  #884  
Old 08-20-2015, 09:57 AM
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Re: Grand Willys project

X2 on the withdrawal symptoms! I'm starting to twitch!
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  #885  
Old 08-25-2015, 04:31 PM
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Re: Grand Willys project

This is an incredible thread and an unbelievable project. I am blown away at the craftsmanship and can only dream of being able to work on vehicles in this capacity. Thanks for taking time to share this wonderful project with us, it truly is awesome.
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  #886  
Old 09-02-2015, 06:05 PM
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Re: Grand Willys project

Glad the updates have been missed.
But a few days after that last post I made I left for the UK and have been travelling right around England, Scotland, Northern Ireland and even around the Republic of Ireland. Back in England right now but about to move on to more of Europe so be a while yet before any updates. Haven't forgotten about the project though as have been buying more tools for my souvenirs instead of caps and t-shirts etc.
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  #887  
Old 09-03-2015, 09:06 AM
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Re: Grand Willys project

Marcus,

While we all miss the updates, I'm sure all of us want you to enjoy your R&R! Stay safe and we eagerly await your return!
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  #888  
Old 09-03-2015, 05:46 PM
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Re: Grand Willys project

Quote:
Originally Posted by sonofasailor3 View Post
Marcus,

While we all miss the updates, I'm sure all of us want you to enjoy your R&R! Stay safe and we eagerly await your return!
Thanks mate.
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