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  #889  
Old 10-07-2015, 06:04 PM
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Re: Grand Willys project

I'll come back later then. Lol
Safe trip though. Hope you had a good one.


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  #890  
Old 10-10-2015, 07:19 AM
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Re: Grand Willys project

I'm back!


Been stripping the doors since I got back from my European holidays. This is probably the worse door as far as rust goes. Bottom step is completely gone and will have to be replaced. Will have to be a 'Z' shaped piece that needs to be straight one way but curved the other which makes it harder to reproduce.


The other side is no better and every door will need some of the skin replaced.


Spent some time working out which door had the better front section verses which had the better rear section.


Now I still have 4 doors but two have grown by 7" and two have shrunk by that much! Maybe the little ones might be good for someone doing a dual cab version. . They are just sitting there and have not been tacked.


This gives you an idea of how I am making the doors 7" longer to suit the cab extension. If you compare the two back pieces you can see the extra length in front of where the door handle sits


I will mix and match the door tops to get the best pieces to make the longer window frames. Not only has to be 7" longer, but extra length needed due to the 2" chop. I will only need one weld seam doing it this way just like the doors.


Just balanced the pieces there to get a shot of what it will look like. I have cut it over size by one door gap so I can trim away the extra to get a perfect fit up for tig welding. Least there will only be the one seam.


Bit hard to see but the centre rib has been crushed at one point and will need to be fixed. Also shows the door has been sucked in as well as should be parallel with the rest of the skin.


Should not be a gap under the front of the ruler but is due to the flattened rib in the middle.


Clamped some solid round bar into the vise that matched the profile. Hit down each side to raise the rib back up.


Looking a lot better now. Also pressed down on each end of the door by hand to get the curve back in again. Just moved a long a little at a time so the end of the rod would not cause a crease.


Checking to make sure the rib curve is the same with the ones each side of it.


Here is the good rib I was comparing against.


Checking to see if all the same height.


The whole way along was checked.
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  #891  
Old 10-12-2015, 08:21 AM
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Re: Grand Willys project

WELCOME BACK!!
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  #892  
Old 11-08-2015, 04:58 AM
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Re: Grand Willys project

I have been spending many hours on it every week but just not very photo worthy just stripping paint and putting them through the citrus acid bath. Might put a few up later if I get a chance.

One thing I can share is last night I bought a Australian Army Trailer from 1945. Called a No.4. This one was made locally by Ford but they were also made by GMH at the same time.


Years ago when I was deciding the length of the cab extension, I made sure I had enough frame left to use a trailer tub from one of these as my bed. Thought it would be nice a different and tie in with the theme that I am going for.


Will have to do a tailgate conversion on it to make it easier for the dog to get in and out. Was going to use my Willys tailgate, but that is a lot shorter in height. Will see what ideas come up.


Stripped of paint and some minor dents taken out. Still needs a bit more work but has been soaked in citric acid since and got all the surface rust from inside the tubes out as well. Not sure how to incorporate this into the trailer tub?
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  #893  
Old 11-08-2015, 12:30 PM
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  #894  
Old 11-15-2015, 07:03 PM
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Re: Grand Willys project


Took a break from stripping paint and tackled this dent on my Willys bumper.


Can see the distortion in the reflection and also the damage on the underside.


I just did it this way. Using a soft mallet on the stump so both had some give and wouldn't stretch the metal.


With most lifted it was on to more detailed work. Used a matching curved dolly and a flat faced hammer on top. I had the bumper sandwiched between the base boards of my house at one end and jammed into my stomach at the other while the middle rested on the stump. This was so I could push up hard from underneath with the dolly while tapping around the outside of the dent with the hammer from above. Pushing up harder than you are tapping down off dolly will raise the centre.


The metal is way too thick to use my bullseye pick hammer, but I used it to mark exactly underneath where I had a tiny amount of a crease left on top.


Then I line up the marks from the bullseye pick over the crack in the stump and then hit down, with the new hammer I bought while over in England recently, to hit on the marks.


Can see it has come up pretty well and have done no filing. Just light hand sand to show up any low spots.


Still got to get a little bit more on the side which I will do over a piece clamped in a vice to lift it.


Do have some rust damage to deal with. The citric acid will take the rust away but leave rust free pits behind. The backside is also effected in the same area so don't want to thin it by filing both sides smooth. Maybe cut a new piece to weld in or try filling the pits with weld? Don't know how much extra it will add to the re-chroming cost to fill them with copper?
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  #895  
Old 11-16-2015, 01:53 AM
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Re: Grand Willys project

Subscribed😄


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  #896  
Old 11-28-2015, 04:29 AM
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Re: Grand Willys project

A little update.

Think this is the last major original pieces to be chopped up. This is to make the grille nearly 9" wider overall.


So this is my new 10 slot grille just balancing together for the photo. Still need to add a couple of inches each side in the headlight area yet.


Can see with the original 1958 8 slot grille next to it how much wider it is.


The 1948 10 slot grille next to it. So it keeps the tie in with that and the age of the chassis and original cab too.


All together it is easier to see the differences. Thinking I might leave the horizontal grille bars off too, but we'll see.


Left over pieces might be good for a golf buggy or rock crawler.
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  #897  
Old 12-04-2015, 03:07 AM
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Re: Grand Willys project


Just thought I would pass this on in case others grind outside like me too. I was cutting the grille apart right at the end of the day. Just getting another thing done quickly, like you do sometimes. Packed up went inside and 30 minutes later I thought I could hear the neighbour's bike idling away. Took no notice until I heard the window in the kitchen suddenly smash. My wife took a look and shouted FIRE! I just raced for the front door and around the side of the house to find flames right up into the eves! Ran for the hose and got the fire out quick smart but just glad we were home. I had fitted cement impregnated weather boards which are fire resistant. If I hadn't we would have lost the house for sure! Sparks had set some wood chips alight under the barbeque stand that I use to put the grinder and tools on. The stand caught alight and then set the window frame on fire.


Had spare boards so replaced the scorched ones. Cut part of the window frame away and replace it.


Wasn't going to risk another wooden stand this time! Decided to make a new bench instead. Re-purposed the neighbours swing set for the two main beams. Cross members were made from someone else's bed frame they had thrown away. Also added some flat stock supports that came from our old balcony railing.


Laid 1/2" thick fibre cement board down and then 3/8" thick floor tiles for the top. Nothing fancy but it is now fire proof and will serve its purpose well enough. Going to replace the wood chips with crushed rock soon too.
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  #898  
Old 12-04-2015, 10:35 AM
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Re: Grand Willys project

WOW! Happy things turned out well for you. It could have been a disaster and once again you taught/reminded us of what CAN happen.
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Old 12-05-2015, 05:28 AM
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Re: Grand Willys project


Made up a new batch of citric acid to strip the rust for all the remaining panels. I use 1kg acid to 10 litres of water. That is about 1lb acid to a gallon of water.


I hadn't stripped the over spray inside the roof channel here where some red oxide paint was. When you pull it out it looks like the acid hasn't done anything as you can see the rust above it as well.


A few seconds with the pressure washer and it is like this. Just a few bits of red oxide left and all the rust gone. Paint has to be a bit flaky or have rust under it to work come off in the acid though. Good paint will stay there.


Love seeing the difference it makes. Can see the 'tide' mark clearly.


Half a front guard done.


A week later the rest.


Free of rust now as the rust left beforehand was even after a strip disc had been over it and couldn't remove it. Blasting would not have got it out of the seams either which acid does a pretty good job of. If it can soak in there, it should remove it. No warpage risk as well.


A popular custom mod is rounding the corners of doors and bonnets etc, not sure if it suits the boxy Willys Truck or not? Here is a version made by Mitsubishi that has similar doors but a CJ3B front. Gives an idea what it would look like.
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Old 12-05-2015, 11:58 AM
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Re: Grand Willys project

Are you chopping the truck? I can't remeber if you are or not.
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