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  #949  
Old 07-26-2016, 06:14 PM
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Re: Grand Willys project

Keep em coming chap. 👍


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  #950  
Old 07-30-2016, 07:27 AM
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Re: Grand Willys project

Really enjoyed this week as was good to see it taking more shape.


Time to try out the upper part of the wall to make sure they are exactly at the same height as each other. Had to take nearly 2 millimeters out of the right side to get it sitting perfectly level across the top of the window.


Strangely both sides of the lower part of the window angled up in the middle? To get it parallel with the top, I shrunk both sides at the corner of the bottom edge to pull it down. Then had to retrim the bottom edge.


I have the level hard against the edge of the door to make sure the door opening stays square to the door pillar. The back of the door is perfectly straight so can do this.


Tacked and ready to grind down the tack welds flush, inside and out, so I can run over them as I tig weld. If I don't do that I can feel the hard spots left during planishing, leaving uneven stretch.


The tig weld pulled hard when shrinking during cooling, but easily fixed by plashing to stretch the weld back out again.


Had a section marked in chalk where it was still pulled in a bit.


Hammering from the inside out against this steel block got all but a section above the weld area flush.


Used the shrinking disc on the inside along with compressed air to cool it to push the low spot outwards.


Nice and flat right across now.


As I was tacking the other side, this end lifted even after plashing the tacks as I went along. So stopped to rectify it.


Fully tig welded the section tacked and then planished only the area around the side to raise that part which brought this end down back to perfect.
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  #951  
Old 08-01-2016, 09:29 AM
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Re: Grand Willys project

Damn this is getting exciting now...

Thank you
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  #952  
Old 08-07-2016, 05:51 AM
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Re: Grand Willys project


Finished the other side off so getting there.


Have to make the pieces in between now. The curves outside the window frame are different to the ones on the inside. Two pieces make up the bottom and four pieces for the top.


One of the stake dollies I made fits quite well so will use this to form the outer window curve.


Just marked where I wanted the curve to start and used a lead working bat to quickly form the bend. Leaves no hammer marks and less than 2 minutes work. I picked this one up last year in England at an old hardware store that was closing down.


Quick fold at the top and tacked into place. Will trim the excess later at the top once the inside flange is attached.


Tig welded into place.


Inside window flange taking shape. Bottom flange just needs to be trimmed off to length.


My wife bought me this old Australian made spot welder as a gift. Thinks I will get plenty of use out of it when I build her a custom car next! Thing weigh a ton but works really well. Came from a business that was closing down making stretched funeral cars!


Feels like cheating as does it so quick and easy. No timer so have to keep a close eye on it as will burn holes right through both layers otherwise!
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  #953  
Old 08-13-2016, 07:20 AM
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Re: Grand Willys project


The upper frame work has an extra strap that runs underneath everything. So I first welded this to each side to make sure I could get to it. Level is clamped in to keep everything straight as the glass wont bend!


Made a new upper piece for the window and this was folded over the strap and spot welded to it like factory.


Next was the very top piece that is also part of the gutter that the roof skin sits in. It sits in a channel so I made one for it.


Added the other folds it needed and hammered over the gutter edge over my smallest diameter T dolly.


All three layers are spot welded together and did both rows with the same spacing as factory. I spot welded it in before the inner window frame was finished to be able to get to it.


Inner window frame pieces are all welded in as well now. Actually drilled out the upper factory spot welds and rewelded it as it hadn't been put on level at the factory.


Rear window and wall all finished for now. I'm glad I made the window wider and did not shorten the height at all. Looks nice and chopped as it is and actually have more window area than stock!
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  #954  
Old 08-20-2016, 08:41 AM
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Re: Grand Willys project


Time to start chopping 2" out of the door window frames.


With the rear wall cut lower down than the cut in the window frame, I will have to address the angle so it bends in the same spot. If I should ever do one again, I will line the cuts up from the start.


At the same height as where the rear wall was sectioned, I cut into the window frame. Didn't go all the way through so I would get a smoother bend.


Now the window frame lines up perfectly.


There was a slight taper to the window frame, so rather than cut slots to shrink the wider section, I stretched out the upper narrow section to match by hammering against the T dolly.


Used a offset bolster to move the fold to match and stretch the corners as well.


Lines up well enough now to blend in.


Was able to weld all the way around to get full strength.


Angle matches the rear corner as well.


Now weld it up and then to extend it forward to meet the front of the door. Not only have to add the 4.5" that I made the door longer, but extra due to the chop as well.


Due to the curve in the door, but flat on the inside, I had to pick the best place to cut it through that it would still match up with the new front section without ending up with two widest points!


With the edges being straight, I could slowly trim up the new piece until it all lined up with the rulers. The backside will be checked as well to make sure that stays flat and true.


Fortunately it worked out well that differences in the age of the pressings of the door top worked in my favour and was able to match the 1948 rear section with the 1958 front section with the extra length needed. Nearly there in this shot. Doing it this way saves having an extra join in the top of the frame.


The other side was completed as well. Thought I was finished but noticed below where I had made my join that there was some lead fill there.


Removed the lead and found a bad repair job that only had a few tacks holding it together!


Cut the whole affected area out as had been ground quite thin previously. Also my digital level gauge showed this was tilting at the different angle to the back of the window frame. That would be bad for the glass as would jam up and not run smoothly.


Welded in a new piece and got the angle to match so all 4 window frame sides were exactly the same.


Now with the window frames done I will have something to line the A pillar up against to get even door gaps.


Starting to get a bit of an idea how it all will turn out.
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  #955  
Old 08-20-2016, 12:42 PM
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Re: Grand Willys project

She's looking good, Marcus. Amazing craftsmanship. Are you going to give her a name soon or wait for her personality to fully shine through first?
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  #956  
Old 08-21-2016, 04:34 AM
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Re: Grand Willys project

Quote:
Originally Posted by Governor View Post
She's looking good, Marcus. Amazing craftsmanship. Are you going to give her a name soon or wait for her personality to fully shine through first?
At the moment just refer to it as GrandWillys. A bit of tongue and check there but is half Grand Cherokee and Willys Pickup.
Not sure if it will change from that.
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  #957  
Old 08-27-2016, 08:16 AM
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Re: Grand Willys project


Top of the A pillar now which can be lined up with the front of the door window frame. Also notice that the lower part of the windscreen to cowl joint is going to need some work with the 2" section already cutout in between.


Started to hammered the cowl back, all off dolly, as didn't want to stretch the top edge at all. I'm am collapsing an arc inwards, so needs to shrink if anything, to move that way.


Had to make sure that the angle didn't change at all as you can't twist glass to fit. Strain on the glass seal will cause leaks as well.


Flows quite well I think.


Not happy with the top angling up so high and wanted it to match the shallower rear angle. I supported the corner so the pillar angle didn't change before attempting to bring it down.


Placed a block of timber on top before giving it a few quick raps with a lead filled rubber mallet. Now matches the angle of the rear wall exactly. Total rise is 1/4" and not flat like you would think these to be. Water will drain now to the front outside corners where the drain cutouts in the gutter are. I had also set the roof skins up with the same rise front and rear when sectioning around the perimeter and wheeling up the new centre.
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  #958  
Old 08-31-2016, 02:11 PM
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Re: Grand Willys project

More great work. This is my favorite thread. Keep them coming.
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  #959  
Old 09-07-2016, 02:01 PM
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Re: Grand Willys project

Just skimmed through the 20 pages of build (my posts per page are set to 40). AMAZING!! I wish I had this level of experience and worksmanship!

I am now subbed to this thread! Please continue with the project, I will be keeping up on this.
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  #960  
Old 10-26-2016, 07:01 AM
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Re: Grand Willys project

Alright, Marcus. It's now been 2 months since your last post and I just wanted to be sure everything is OK with you. I know that you had some medical issues earlier in this thread and hope all is well my friend.
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