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  #973  
Old 01-06-2017, 05:48 PM
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Re: Grand Willys project

Small one is auto headlights. Maybe sat for the other one?


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  #974  
Old 01-06-2017, 11:15 PM
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Re: Grand Willys project

The long one is the LED's for the front parking/proximity sensors.
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  #975  
Old 01-07-2017, 01:42 AM
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Re: Grand Willys project

Many thanks guys. I plan to incorporate both into the Willys build.
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  #976  
Old 01-08-2017, 06:42 PM
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Re: Grand Willys project

Back from holidays after seeing Christmas and the rest of the year out while camping by a river in the bush. Nice way to spend the hot summers days away from the hustle and bustle.
Been hard in the workshop since back though with it being 38*C/100*F inside!


As I will be using as much from the interior as possible from the donor, I will be adding this support frame that goes from A pillar to A pillar. It took some of the impact from the Harley hitting it side on at 100mph, so needed some straightening first on the end bracket and lower frame.


I fitted the brake pedal as it bolts between the firewall and the lower cowl as I wanted that to be at the correct height. Can also see the two studs that the support frame I am adding next bolts to.


After straightening the frame I could bolt it into the lower cowl and also the studs on the transmission hump. The tube is very strong and did not bend in the impact. It is 52x5mm-2"x5/16" mandrel bent tubing. The frame holds the steering column, satnav, climate controlled air-conditioning, glove and fuse box etc.


Can just make out the vertical face of the main mount for the frame over by the louvers. I will have to add something to stretch from the A pillar right to the firewall. Going to utilise the tag that is in the middle of the A pillar as well for an extra mount.


I had kept the original donor mounts for this purpose but have to modify them to suit my setup. Can see the stock one on the right and how I have altered the other one.


I have bent up a new upper panel out of 1.2mm-18g sheet to take the mount. Spot welded it to the original A pillar piece from the Willys. Decided to add an extra mount also for the frame and the captive nut will get welded behind the hole which will be inside the A pillar itself.


This adds a lot of strength to the A pillar to take the weight of the longer doors I have. The panel is plug welded to both sides of the A pillar and also to the firewall and lower cowl and kick panel.


Both sides now done. Next will be to make a filler panel between the lower cowl and the upper one as all has to be sealed off for my fresh air intake which draws fresh air in from the louvers I cut into both cowl sides.


I had only this piece left from the donor cowl that attached to the lower and think it will be just enough. I traced its outline onto some cardboard so I would have somewhere to start.


My CAD, cardboard aided design, will give me a line on which to tip a flange across the top under the Willys cowl.


It is getting there. That thick white sealant is not my work BTW. It is factory Jeep work from 2008!


The piece has now been spot welded again to the lower cowl and glued with panel adhesive to the underside of the Willys cowl.


The ends have also had patches shaped and welded into the new piece of the cowl and the A pillar.
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  #977  
Old 01-14-2017, 05:30 AM
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Re: Grand Willys project


The heater-A/C unit took some damage in the accident. It is attached to both the firewall, in three points, as well as the inner frame in 4 places. The side impact moved the frame and broke all the firewall mounts and one on the frame itself. I made inner and outer sheet metal reinforcements that were riveted on, sandwiching the original plastic in between.


The unit only just clears the cowl which will make the ducting a bit difficult.


Can now see how the frame bolts into the new mounts I made above the kick panels.


Also the extra ones into the A pillars. They brace the pillars left to right very well now.


All original mounts are used between the firewall, and the frame for the heater-A/C unit and the frame to the lower cowl, upper kick panels, transmission hump and the extras in the A pillars!


While things are getting laid out and still are accessible, I looked at where the wipers can go. There is just no room for them in the cowl area like I suspected.


I could maybe flip it upside down and put the donor unit into the header panel. Have the pivot points come in below the gutter in the middle of the panel above the windscreen.


I would have to cut a lot away to fit it into the header panel and then make a new frame over it to put the strength back. Even sunk all the way the motor would still sit up about 50mm-2" above the header. I checked the roof panel height and it would still clear it though.


The only problem is that the wipers would now park vertically which I don't want. Reversing the polarity only works if the housing is not grounded, so would have to check that to make the motor turn the other way. Some gear boxes have a parking plate that can be turned 180* to alter the park position, otherwise a LHD one would work as they rotate in the opposite direction and are a mirror image of this one. A universal cable driven wiper unit might work but heard they are not as good as a OEM linkage arrangement?
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  #978  
Old 01-15-2017, 06:19 PM
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Re: Grand Willys project

Wow. I kind of get the feeling that the can of worms is opening. 👌
Outstanding work as always. Have been recovering forum a heart attack and feared I would not see this one through.
Well done.


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  #979  
Old 01-16-2017, 12:58 AM
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Re: Grand Willys project

Quote:
Originally Posted by UKWK View Post
Wow. I kind of get the feeling that the can of worms is opening. 👌
Outstanding work as always. Have been recovering forum a heart attack and feared I would not see this one through.
Well done.


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So glad you made it through mate. More than just to see this build out too!

Solution for the wipers I think will come from your side of the pond actually. 2007 on Land Rover Defender whole wiper setup would suit this perfectly. Maybe earlier too but needs to be a 2 speed motor. Just trying to find a complete setup at the moment second-hand.
Know of any online wreckers for LR's?

Otherwise a Jaguar XJ6 or 12 would be a possibility too.
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  #980  
Old 01-16-2017, 02:00 PM
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Grand Willys project

Equicar 4x4 breakers. UK
Try them. Usually got a lot in stock.
http://www.equicar.co.uk


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  #981  
Old 01-16-2017, 11:07 PM
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Re: Grand Willys project

Thanks mate.
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  #982  
Old 02-04-2017, 08:17 PM
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Re: Grand Willys project


I don't actually have a photo of my donor dash as it had been partially pulled apart for some reason after it was written off. So here is a picture of what I hope to fit, but mirror image, of a 2008 Jeep Grand Cherokee Limited. No classic gauges on this build as going for the 1948 outside but 2008 inside theme to keep things cohesive.


The underside has all the ducting but wont actually fit in due to the shape of the cowl and that the defrost is at the wrong end of the dash.


With my wife armed with the heat gun and me using a stiff spatula, was able to break the plastic welds holding this to the top half.


Cut out just want I needed and then shaped it to fit under the cowl. Will have to make a new top cover for it to direct the airflow.


As the cowl is curved, shaped up some thin sheet to match.


Testing to see how it was coming along. Just good bit of practise on the English Wheel.


Used a trick Peter Tommasini taught me and tipped the fold on the wheel


Run sealer under it before adding the rivets as well to hold it in place.


That should do the trick


Fitted in under the cowl matching the curve. This has the four outlets for the cabin heat and A/C. One each side of the SatNav/Media screen and the other two to go to each end of the dash.
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  #983  
Old 02-11-2017, 03:19 AM
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Re: Grand Willys project


Thanks also for the suggestions on getting rid of the dents left in the leather. We had a couple of 38*C/100*F+ days so left the hood piece in the sun and put a drop of water in the indentations. They lifted right up on their own with barely a trace left.


Couldn't find any vents that would work in the tight space I had to come up in behind the instrument panel. Thought I might as well try to make some. Wanted to fit a 2" hose so made the short end half the circumference. The other end the maximum width I could fit above the instrument panel plus enough for half the depth of the vent opening.


As the two halves need to be mirror images of each other, I first ran one through the stretcher on three sides and the other the shrinker. No hammering at all done yet. Easier to feed through the machines, especially the rounded end.


Just turned the edges over by eye.


Used this hammer over a sand bag to help start the curved end.


Refined the shape over some pipe.


Flared the ends over for some area for the spot welds to attach it to the dash support later.


Welded the two sides together.


Ready to try out.


Fits in just nicely over the instrument panel and curves down the backside of the cowl.


Another was made for the other side so the pressure difference would be the same left to right.


Want to say a big thank you to Bob Daley who showed his wife Suz this build. They sent over this Willys Overland workers badge from her Grandfather who worked in the plant and quite likely help put this Truck together in 1948! Not only that but also her father too was there around that time. I hope to find a good place in the cab to fix this once it is finished.
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  #984  
Old 02-11-2017, 06:35 AM
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Re: Grand Willys project

Looks like a real fun project, wish I could lent a hand
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