My Willys 3A and 3B Community
Your Projects => Your CJ-3A Project => Your Modified 3A Project => Topic started by: Trenton on November 23, 2015, 11:34:16 PM
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Well I picked it up 3 weeks ago in pretty solid shape and almost all original except the PO had converted it 50% to 12v. The previous owner had parked her in 1980 in his huge garage, he put a battery in and she cranked over and started right away still on the 35 year old fuel. he has already put new wheel cylinders and master cylinder as the brakes were frozen solid. The plan is to keep the build very budget friendly. I set aside $5000.00 Canadian and the plan was to get her road worthy for that much including the purchase price. Any money I can get back out of it for selling off parts like the complete rear PTO can then go back onto the budget. These are few and far between in Canada and costly if in good shape, I paid $3800.00 for it so that just leaves me $1200.00 for the build which I have pretty much used up already and I still need some parts so I may have to slow down a little. Its not a restoration or a hot rod, I'm trying to keep it as original as possible while also going the cheaper route when I can. All work is done by me.
pic from for sale add
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0045_zpsx0nkpqzf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0045_zpsx0nkpqzf.jpg.html)
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ok so we drove 15 hours to pick her up (http://i963.photobucket.com/albums/ae114/buggysale/IMG_0026_zpsmmfz7ua8.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0026_zpsmmfz7ua8.jpg.html)
my buddy and i couldn't resist unloading her and going wheeling in the rain on the return trip... don't forget she hadn't been driven for 35 years (http://i963.photobucket.com/albums/ae114/buggysale/IMG_0034_zps7znjryhf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0034_zps7znjryhf.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0039_zpsz2gghl2j.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0039_zpsz2gghl2j.jpg.html)
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home successfully and that ugly roll bar removed
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0027_zpsbelgruim.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0027_zpsbelgruim.jpg.html)
my nephew approves (http://i963.photobucket.com/albums/ae114/buggysale/IMG_4319_zpssctlozo0.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4319_zpssctlozo0.jpg.html)
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first thing is a complete tune up and replacement of parts i think may fail. I'm not doing a historically accurate build, i want quality and reliability over all.
so thermostat, rad cap, upper and lower rad hoses, plugs, wires, cap, rotor, coil(12V with built in resistor), starter re-wound to 12v, replace generator with one wire alternator, battery, ignition switch, remove voltage reg., replace all wiring and i do mean ALL. belt, water pump and re-core the rad, new gauges and senders so I can actually keep tabs on the Willys workings. also oil and filter, air filter, fuel filter...
pulled the oil pan, straightened it, primed, painted and re-installed
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0001_zpsecreokfp.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0001_zpsecreokfp.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0003_zpsq7nyaty5.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0003_zpsq7nyaty5.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0008_zpsrudiaryo.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0008_zpsrudiaryo.jpg.html)
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modern thermostat with homemade spacer and 4 x 1/8" holes drilled in it (http://i963.photobucket.com/albums/ae114/buggysale/IMG_0004_zps6xmod19x.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0004_zps6xmod19x.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0006_zpsxfehj89p.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0006_zpsxfehj89p.jpg.html)
K&N air filter replaces oil bath, yes the hood closes (http://i963.photobucket.com/albums/ae114/buggysale/IMG_0050_zpsxevtlium.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0050_zpsxevtlium.jpg.html)
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old wiring (http://i963.photobucket.com/albums/ae114/buggysale/IMG_0051_zps26teeehu.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0051_zps26teeehu.jpg.html)
$80.00 for Painless harness from Summit, 4 switched circuits and 3 constant, also put in new started solenoid.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4422_zps5pz6ciqy.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4422_zps5pz6ciqy.jpg.html)
alt installed, i made a mount using part of the old generator brackets
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4423_zpsko58baxj.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4423_zpsko58baxj.jpg.html)
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misc photos of cleaned up and changed parts (http://i963.photobucket.com/albums/ae114/buggysale/IMG_0011_zpsump1so1s.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0011_zpsump1so1s.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0007_zps2wjd2ran.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0007_zps2wjd2ran.jpg.html)
the starter i had rewound at a local auto electronics shop to 12v. they also rebuilt and repainted it. they left on the original tag for me. (http://i963.photobucket.com/albums/ae114/buggysale/IMG_4439_zpsqqbtk3sg.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4439_zpsqqbtk3sg.jpg.html)
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in keeping with the budget theme i used a Safari top from a YJ i had laying around and the windshield channel and welded together 2 weight bench bars for the bow.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0025_zpsfqm8bblc.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0025_zpsfqm8bblc.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0024_zpslb1gq3bd.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0024_zpslb1gq3bd.jpg.html)
also used an old ARB air compressor i had from a previous build and she now has on board air so i can air down these rock hard tires for trail use(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4425_zpswpr3ngbd.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4425_zpswpr3ngbd.jpg.html)
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got a set of 3 auto gages on sale for $85.00 and the senders from the oil pressure and temp fit just fine. also i like the red lights. hey does everyone have a red high beam indicator lamp? i didn't know what it was until i changed the bulb and it actually worked.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0058_zpsk5olvyi3.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0058_zpsk5olvyi3.jpg.html)
I'll be removing the throttle lock from the dash and then using the cable to connect to a hand throttle lever that i mounted on the transmission shifter for starting out offroad on a hill.
So after all the tune up parts were changed I flushed the rad and filled her u with fresh coolant and blammooo, about 47 leaks. so today i dropped the rad off at a great local shop that will re-core it for me for less than buying a new one and they are right around the corner and give warranty and stand behind their work. ill post pics of the new rad when i get it back.
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this is the rad and shroud this morning before dropping off rad at the shop, by the reading i've done the shrouds are often missing or damaged? this ones perfect, just needs cleaning and paint.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4473_zpsazmhocny.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4473_zpsazmhocny.jpg.html)
i've got a remanufactured water pump on the way and the rad should be back in a few days so once they are back installed that will be it for the engine and electrics, she should be reliable then.
i am also making front and rear bumpers and installing an M8000 winch and tow points. of course i still need to go back to original style seats and get some tires. I'm unsure on the tire plan, i am thinking a modern tall skinny agressive radial so i can air down for comfort offroad but you can't beat the look of the non-directional military tires...i'm torn.
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today was a busy day. finally pulled the PTO off the T-case and installed the cover plate. changed the T-case fluid while in there, remembering this thing was parked for 35 years the color and smell of the fluid wasn't too pleasant. also pulled the fuel tank so i could inspect its condition and try to get the fuel gauge sender going again. good news is the fuel tank is in great shape, bad news is the Willys floor isn't so great. I also finished up all the under dash wiring and majority of the under hood wiring. On board air is running.
interesting cork float on the sending unit (http://i963.photobucket.com/albums/ae114/buggysale/IMG_4482_zpsreqlljvf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4482_zpsreqlljvf.jpg.html)
i think this seal is LEAD (http://i963.photobucket.com/albums/ae114/buggysale/IMG_4483_zpshczu3ywb.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4483_zpshczu3ywb.jpg.html)
the tank looks ok (http://i963.photobucket.com/albums/ae114/buggysale/IMG_4486_zps9mimqof2.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4486_zps9mimqof2.jpg.html)
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looks like over the years the steel around the wood has gone and someone tried to bondo it a long time ago. i guess i'll be doing some sheet metal work :'(
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4485_zpsiv9k1nqf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4485_zpsiv9k1nqf.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4484_zpsyap4gseg.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4484_zpsyap4gseg.jpg.html)
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Trenton,
Very interesting and the red lights on the gauges looks neat. The Jeep appears to be in really good shape � great find! Did you check compression and what kind of oil pressure do you have?
Oh and of course you know that now you have just hooked another young soul that will remember the first time he ever got behind the wheel of a Jeep. Better start looking at another project for your nephew!
Keep the pictures coming and congratulations.
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got the rad back today, the only salvageable parts from the original rad were the side rails and the bottom tank. the shop had to replace the complete core and the top tank. they had asked if i wanted the top tank to look like the original curved upper (more money) but i told them i was happy with a squared top so thats what i got. the upper and lower hose mounts are in the exact same locations, the side mounts are the same and the original shroud fits. the overflow was completely blocked off, the lower part of the rad was almost totally closed off too. this should cool a lot better with the new water pump installed. will get pics of it in the jeep.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_2425_zpsdqi8rr2s.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_2425_zpsdqi8rr2s.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_2462_zpskgqdmodk.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_2462_zpskgqdmodk.jpg.html)
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well progress has been slow last couple days. i relocated the horns to behind the grill to clean up the drivers side inner fender. painted them black so i hope they kinda disappear from sight in there. the water pump came in so thats installed. painted and installed the shroud and radiator. i changed the drain spout on the passenger side of the block... when i first opened that spout nothing came out of it. so when i pulled the water pump i got a dental pick in there and with a lot of water flow and some air pressure i managed to get water flowing again. i hope the rest of the block isn't plugged up with rust and crud still, especially with new rad and pump on there. well with this work done I'm finished under the hood, now i can stop putting off the floor repair.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4516_zpsnx4dybvs.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4516_zpsnx4dybvs.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4514_zpsmowb97kq.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4514_zpsmowb97kq.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4520_zpso1zso2n8.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4520_zpso1zso2n8.jpg.html)
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hopefully no more work under here for a while. i put some rubber sheeting between the rad and mount to try and eliminate any chafing. i also got some 3/16 thick reinforced rubber from a buddy i'll be cutting into new body mount bushings as the current ones are either missing or just junk. i think the rad looks pretty good in there, it may not be totally original but this isn't a Barret Jackson build;-)�
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4517_zpsyj8jjhmr.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4517_zpsyj8jjhmr.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4519_zps9eytlxlb.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4519_zps9eytlxlb.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4518_zpsgip660fs.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4518_zpsgip660fs.jpg.html)
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drivers side floor template
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0064_zpspgar2j9k.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0064_zpspgar2j9k.jpg.html)
passenger floor template (http://i963.photobucket.com/albums/ae114/buggysale/IMG_0065_zpslxczjxfy.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0065_zpslxczjxfy.jpg.html)
kept going on the drivers floor...not looking good. i know its not the preferred method but my repair plan is to tac weld the existing floor steel i have cut back to the hat channel, reinstall the wood then sheet the whole under seat and floor area in 18 gauge steel. i will bead roll it and bend up a lip or flange all the edges of the new plate. should be solid and not flexible... remember i am building a driver/wheeler, not a restoration or Ferrari. i will also drill a bunch of holes in the new floor plate so it can be plug welded to the existing floor below it. I'm confident it will be strong and lasting.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_0068_zpsse7ybs2q.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_0068_zpsse7ybs2q.jpg.html)
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in the spirit of continuing to put off the floor repair, today i cleaned up and painted the t-case skid i had removed earlier and I also cleaned the fuel tank to bare metal, checked it for damage, went over all the seams with fuel safe seam sealer and then primed and rock guarded it. the PO had used some soft rubber lines in the fuel system so I also got new hard lines and bent and fitted it so when i re-instal the tank it will be much more reliable and safe.
i guess tomorrow i have to keep going on the floor fix. ;)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4545_zpssz4ru0wg.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4545_zpssz4ru0wg.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4556_zpsv9gukyfj.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4556_zpsv9gukyfj.jpg.html)
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well i finally got to the floors today. cut the insert pieces out of 18 gauge, fit them and marked them for the beads and flanging. cleaned the existing floors up and prepped everything for welding. i need help with the bead roller because mine is a two person job and some how all my buddies made themselves busy today :( so tomorrow i have ensured one of them can come crank the handle on the roller for me.
passenger (http://i963.photobucket.com/albums/ae114/buggysale/IMG_4564_zps42ux2tec.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4564_zps42ux2tec.jpg.html)
driver, this side had to be two piece due to size of sheet metal i had
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4562_zpsgufsdbtv.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4562_zpsgufsdbtv.jpg.html)
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well today was productive, got all the insert pieces bead rolled and flanged, installed drivers side pieces. still have a little welding to do on that side and then do the passenger side. i will clean up the welds a bit and then use some seam sealer to smooth it out and coat it with paint. that floor pan will be completely waterproof except the drain hole on the side of the tub and of course the two holes under the fuel tank for drain and fuel line.
the existing steel i ground to bare metal and then sprayed it with weld through primer. also ran some seam sealer around all edges before pressing in the new sheet metal. trying to keep it a bit waterproof.
passenger floor
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4569_zps8tbxy265.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4569_zps8tbxy265.jpg.html)
driver floor
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4570_zpsemze8chv.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4570_zpsemze8chv.jpg.html)
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rear section of drivers side, the holes are for plug welding it to the existing steel beneath. hopefully water won't get in between the two sheets and rust it out to quickly.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4573_zpsaurjtab2.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4573_zpsaurjtab2.jpg.html)
drivers almost complete
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4578_zpsb14vaybv.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4578_zpsb14vaybv.jpg.html)
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Wow that is really nice! If you want to whip up 10 or 12 of those and send them to me for spares that'd be great ;D
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Your a sheet metal artist Trenton, beautiful work!
What is the reasoning for a double floor (if I'm reading it right), even though you have allowed for drainage, I would think it would be inviting a rust issue.
Like Ryan said your work could be in demand on this page....
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Your a sheet metal artist Trenton, beautiful work!
What is the reasoning for a double floor (if I'm reading it right), even though you have allowed for drainage, I would think it would be inviting a rust issue.
Like Ryan said your work could be in demand on this page....
well the existing floors are so thin that something had to be done. the drivers has several holes but the "hat channel" was not terrible. yeah the best way would be to remove the floor pan and weld in the new sheet metal but in my mind this started out as a patch, it kind of got out of control ;) with the sealer between the two layers of floor and the spray coating thats in there I'm hoping it won't be a problem. this is really a fair weather wheeler for me as it will never have a roof, doors or heater so not a lot of snow wheeling is going to happen, i don't see it getting wet often and it parks inside the heated shop.
i've only ever done one floor before in a 1973 Camaro and it didn't turn out anywhere near this nice so i think the idea of removing the existing floor and ending up with a Flintstone Jeep was always in the back of my mind so laying this one on the old sheet metal was a security blanket. now that i got the basics of the bead roller and flanging down next time i'll just cut out and replace the floor... i hope thats not too soon.
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Your idea may work better than mine which was to repair the floor with 16 gauge galvanized. It was tough to cut, bend and welding it was miserable. Up here in the Northeast our roads are second only to the Bonniville Salt Flats. Trying to stay ahead of the rust takes requires a different approach.
Keep up the thread, I have enjoyed and learned from your work.
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well i finished up the driver and passenger sides today. completed welding, seam sealed all edges, primered...waiting on paint until a few more fixes are done. tomorrow ill reinstall new body mount rubber bushings, gotta repair the body mounts that are in front of each rear tire in the wheel openings.
when i pulled the trans and T-case cover plates off to prep for paint there was 65 years of dirt and grease stuck in there mixed with some grass and i think some hay. must have taken an hour with a scraper to tidy that up.
if your wondering about the floor inside the tool box lets just say its less than perfect. i have limited time right nw and so i felt that getting the foot wells in was most important so it can get back to being drivable. i will have plenty more repairs to do in the future on other areas.
drivers side
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4587_zps8ba1jfll.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4587_zps8ba1jfll.jpg.html)
passenger side
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4588_zps4teblbsg.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4588_zps4teblbsg.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4589_zpszfsctmfw.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4589_zpszfsctmfw.jpg.html)
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Really nice job
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Nice work Trenton.
I was a little concerned with your choice to cover the floor with new sheet metal, but you did a really nice job.� And it's not the first time this approach has been used. (see photo below)
If you think about it, 65 years went by before the first floor needed some repairs.� This will work out fine.
Your bead roller work is top notch.� I wish I could do that.
(http://i1195.photobucket.com/albums/aa397/athawk11/athawk11%20Willys%20White/20130512008_zpsf4583239-1.jpg)
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I was a little concerned with your choice to cover the floor with new sheet metal, but you did a really nice job. And it's not the first time this approach has been used. (see photo below)
If you think about it, 65 years went by before the first floor needed some repairs. This will work out fine.
Your bead roller work is top notch. I wish I could do that.
i think with the preparation steps i took the floors should be fine. if i had pulled the tub off the chassis then i would have cut the existing steel out. this isn't a restoration but a fun, no pressure project to wrench on and do some mild wheeling. buddies are planning a Moab trip sept of next year so i gotta have her ready by then.
as for bead rolling if you measure and lay out your patten on the steel with a sharpie first then its really just time consuming and anyone can do it. mine is a cheap one, it can only do 15" across a sheet so if you can work from both sides i can do a 30" wide sheet maximum. cost $199.00 canadian or like 50 bucks US ;) so when i do the rear tub floor...which i will cut out... i will have to do it in two pieces.
(http://i963.photobucket.com/albums/ae114/buggysale/bead%20roller_zpsutc4k4xn.jpg) (http://s963.photobucket.com/user/buggysale/media/bead%20roller_zpsutc4k4xn.jpg.html)
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ok so while I'm trying to decide what color to paint the Jeep i moved on to repair the body mounts. the two right in front of the rear wheels were completely gone, luckily the frame side of the mounts are fine its the tub side that has deteriorated.
as they started
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4590_zpsh8ydh3j9.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4590_zpsh8ydh3j9.jpg.html)
the 1.5" x 1.5" x 1/8" angle i used cut to fit, who knew there was a drain for the tool box lid lip that comes out right above the body mount bolt.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4591_zpsrbkuib9n.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4591_zpsrbkuib9n.jpg.html)
i pre-drilled the body mount hole and made a few other holes in the angle to plug weld and secure it to the remaining steel on the bottom and then stitch welded it to the vertical.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4592%202_zpsftors4ft.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4592%202_zpsftors4ft.jpg.html)
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then i used my favourite stuff "seam sealer" to ensure water doesn't get between the new and old steel.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4594_zpsb8vit6ij.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4594_zpsb8vit6ij.jpg.html)
and finally the finished product painted. of course now i have two freshly painted spots on the chassis so it makes me want to keep going but theres a lot of other more important stuff to do first. both sides were equally deteriorated so i just did them both the same way.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4596_zps1o8bmvhu.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4596_zps1o8bmvhu.jpg.html)
i also cut up some reinforced rubber matting to make new body bushings. will install them all tomorrow once paint has cured. the new rubber is about 1/2" thick so i will actually have a slight body lift. new body mounts bolts of course will go in. the two rearmost body mounts that go on the rear crossmember are in equally bad shape but i'll leave them until i build a rear bumper.
tomorrow is paint the inside of the tub and then reassemble as much as i can. maybe it will run tomorrow ;D
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Trenton,
Did you really post at 03:32 this morning? You are certainly dedicated my friend.
Remember to send video of your test drive..........
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Trenton,
Did you really post at 03:32 this morning? You are certainly dedicated my friend.
Remember to send video of your test drive..........
i live on the west coast, it was 01:32 here ;) I work in the oilfield and things are fairly slow at the moment so I'm on time off right now but i still wake up at like 06:00 every day so what else to do but work on the Jeep, most days I'm in the shop until 11 or 12 at night as well.
i got a deal on some paint and so started that process today since i needed to paint the new floors anyway. I'm sure its probably cliche to paint a non military jeep green but its what i got and if someone who knows jeeps sees it they will know its not the correct green.
a teaser...
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4600_zpsbblxe4yx.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4600_zpsbblxe4yx.jpg.html)
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well today i knocked a bunch of small jobs off the list. installed antenna and power wires for VHF radio (it will go in an ammo can centre console i am planning), its great to be able to keep in touch with the rest of the group on the trail. drilled 4" holes in the rear of the tub and mounted LED brake/marker lights as well as the license plate light, finished the wiring by running whole new harness from the firewall to the rear for lights. installed the trans, T-case shifter covers in the tub that I had removed for painting, made new cork gaskets for those. found some rubber to use under the fuel tank to prevent chaffing the new steel and paint. bolted the body down on new rubber mounts that i doubled up to give the body about a 1/8" lift over stock.. this is just to ensure it stays off the chassis. i cleaned up and painted the rear crossmember and made the plan for a rear bumper.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4607_zpskffvlp50.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4607_zpskffvlp50.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4605_zpsowyhcafg.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4605_zpsowyhcafg.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4602_zpsz2pmmsv9.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4602_zpsz2pmmsv9.jpg.html)
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and just for kicks i thought i'd see what she'd look like on 4D's... i figure a little sawsall trimming is all thats needed...eh :o what do ya think?
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4606_zps3d0avzsv.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4606_zps3d0avzsv.jpg.html)
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so today was one of those days where you work all day on the Jeep but then at the end of the day it feels like you have accomplished very little.� i drained and filled new fluids in T-case and trans, installed skid plate, installed fuel tank and new hard lines, worked on the hand throttle but need to grab a new cable and then i decided that with the new paint on the back half of the tub I couldn't deal with there being some holes and bad damage where the original spare tire mount was. i cut it out and made up a template so tomorrow i can weld in the new sheet metal.
im not happy with the black rock guard on the fuel tank. it hasn't really gotten as hard as i would like. I'm wondering if in the heat of summer it will even be softer, not good. might have to strip it and paint it with the green... thats a bummer. and speaking of the fuel tank if your wondering about that spot that looks like a giant patch you'd be right. previous owner must have done it, its silver soldered on and was sealing when i pulled the tank so hopefully its all still good.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4622_zps9frzajqx.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4622_zps9frzajqx.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4621_zps8t4a8hnp.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4621_zps8t4a8hnp.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4620_zpss4wj5zwj.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4620_zpss4wj5zwj.jpg.html)
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well i got the patch in and painted. thats it for today.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4628_zps8on4lxkj.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4628_zps8on4lxkj.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4629_zpswph6pmcj.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4629_zpswph6pmcj.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4635_zps6xp5ybfm.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4635_zps6xp5ybfm.jpg.html)
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(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4642_zpspoq6uiuf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4642_zpspoq6uiuf.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4648_zps1g4dlrxf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4648_zps1g4dlrxf.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4641_zpsdvega4br.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4641_zpsdvega4br.jpg.html)
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today i took the day off the jeep but then at about 8pm decided to knock a few items off the list, so i installed the side view mirror, finished the hand throttle, installed front marker lights, made up some hardwood windshield blocks for the hood and installed a new fuel gauge to match the other new gauges. got out of th shop art 04:00... :-?
blocks are but to dimensions i found on this forum but the holes are different to accommodate hardware i had
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4660_zpsm5trul2j.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4660_zpsm5trul2j.jpg.html)
and with the holes drilled where specified in the dimension i found they actually fit the hood, win win.(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4661_zpsc0iwcipz.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4661_zpsc0iwcipz.jpg.html)
mirror is not reproduction correct as its 6" round but its close and was cheap. it will remain the only shiny piece on the Jeep when its complete. i heard each piece of chrome adds horsepower and i think i need all the help i can get ;D
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4658_zpsr7jlg2hn.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4658_zpsr7jlg2hn.jpg.html)
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fuel gauge in, still need sender. also theres now a hole in the dash where i removed the "throttle lock" to use the carbeurator attachment location for a hand throttle thats located on the gear shift.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4659_zpszjh5abqq.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4659_zpszjh5abqq.jpg.html)
once i had installed the new LED markers they were connected to the original location on the headlight switch and came on at the first 'click' of the switch but when i pulled it out further to turn on headlights they went off... i didn't like that.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4652_zpskamrwzip.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4652_zpskamrwzip.jpg.html)
so i fixed it so they come on at first click and stay on when the switch is pulled out to headlights as well.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4656_zpsaqntrob7.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4656_zpsaqntrob7.jpg.html)
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I hate to admit it but I like those lit gauges... Nice work all around.
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the best of intentions as they say... i got started at full speed this morning after being up WAY to late in the shop last night but ran out of steam quickly. so i made a little progress on the bumper but not as much as i should have. the plate the winch will sit on is 1/4" and will be bolted to both frame rails as well as welded to the back lower edge of the actual 4x2 box steel that makes up the bumper. the frame tie ins are 1/2" flat bar and they will of course be welded right through the bumper and become tow points on the front side. the winch rope will run through a slot in the centre of the 4x2, also going to have 2 x 3" holes through the bumper outside the frame rails for driving/fog lights... not that i plan a lot of highway or even night wheeling but i had them for a different project and didn't use them. hope to get this finished up tomorrow.
i've only got 2 days left at home then go away to work for several months so this has to get done NOW!!!
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4673_zpsobbt1as4.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4673_zpsobbt1as4.jpg.html)
in this pic the 4x2 that makes up the bumper is actually sitting on top of the frame tie ins, i will be slotting the 4x2 to slide it over those pieces of 1/2"
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4672_zpsbc4bb7vf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4672_zpsbc4bb7vf.jpg.html)
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today was a slow shop day. i made a little bumper progress, looking at the bumper i need to decide whether or not I'm going to put holes through it outside the frame rails so driving lights will go right through it or just bolt them to the top ends of the frame rails (much less work). I also made a new bracket for the windshield vent, its not perfect but it will do.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4689_zps9tljyjlv.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4689_zps9tljyjlv.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4691_zpsxts7v17v.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4691_zpsxts7v17v.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4690_zpshzz21n1j.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4690_zpshzz21n1j.jpg.html)
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well got the air conditioning fixed ;D worked on bumper a bit. still need to box in the ends and trim the tow points before fully welding it all together. i decided against mounting the driving lights in the bumper because i just don't want to do the work. today was last day working on the Willys for a while, I'm heading overseas for work. so progress comes to a screeching halt as of now.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4695_zpsgmbb0g3z.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4695_zpsgmbb0g3z.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4693_zpssvf7m48f.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4693_zpssvf7m48f.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4694_zpsbfqs2fm3.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4694_zpsbfqs2fm3.jpg.html)
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(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4701_zpspnaqnqzv.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4701_zpspnaqnqzv.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4705_zpsohf5k0ng.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4705_zpsohf5k0ng.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_4704_zpseh0oh20x.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_4704_zpseh0oh20x.jpg.html)
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So in my search for a beefier d-41 diff cover a good point was brought up, why beef this stuff up when ultimately I'd hope to change it out for a stronger axle. Well as I said in the beginning there's a plan here to build the best wheeler possible while staying under a set budget. It's a bit of a competition between a buddy and I who also plans the same kind of build under the same budget constraints when both are complete we will take them out and have a bit of a competition or just some fun really... But I'm gonna kick his butt. With some big expenses already on the Willys that yes I maybe could have got away without doing but I really want reliability so I did all the engine and electronics mods/replacements. All that being said I'm gonna run the existing drive train and axles. So I'm gonna replace the rear cover as mine has holes that have been welded up by the PO but it still leaks and I'd also like to run a rear locker.
So here's the plan, try to find a 32" x r16 bias tire for cheap. Clean up existing axles and add rear lock-right locker and beefy covers. I have a plan for steering as I'm not convinced of the longevity of the stock setup for harder wheelin but I'm keeping that to myself until I see how it works out. With all that in place hopefully ready for a Moab trip sept 2016 I'll go and see how she does.
So who has experience with the 41 lasting with a locker and stock engine and 32" tires?
Sorry I can be long winded but I'm away from home now and got a lot of time to plan and surf the net for parts.
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well i have gotten back from overseas so time to get to work on the Willys. takes me 4 flights and 2 days to get to canada from Vietnam, got home yesterday and relaxed then this morning decided to get up early and get to it. i've had time to plan and order parts while i was away so the plan is to swap in a saginaw steering setup. i have never been one to leave well enough alone and i think this steering swap may turn into more than i bargained for but its too late now. steering box and column came out easy enough but the bracket thats welded to the front cross member that the bell crank attaches too...thats a different story. i won't bore you with details but it ended up in about 45 pieces and i went through half a bottle of oxy/acet. ever have one of those days in the shop where stuff just doesn't go your way? well that was today, after i destroyed half the old steering parts getting them out i decided it was time for a break and left the shop. try to get back to it tomorrow. the reasoning behind doing this now is because i realised that before i finish the front bumper i better get the frame boxed and the steering box mounted.
i will have the remaining steering parts to sell for super cheap once i get this together so if anyones needing an original steering box with pitman arm, tie rods (rod ends are loose i imagine so they would need replacing) and drag link then those parts will be available. I'm gonna use the column and the bell crank wouldn't do anyone any good;-)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5037_zpsbbqekkxq.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5037_zpsbbqekkxq.jpg.html)
looks like the fluid hasn't been changed since 1950 in the steering box.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5039_zpsgevdon5r.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5039_zpsgevdon5r.jpg.html)
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Ive never seen an old one with actual fluid in it.� All the ones ive seen have had a grease fitting installed and packed with grease instead of heavy oil like its supposed to have.
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That is knuckle pudding right there! The steering knuckles take the same stuff.
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so i am waiting for some steering parts to arrive before i move forward on the saginaw swap and i needed to do seats so i started that today. making a 60/40 split bench. the passenger side seat cushion will flip up to allow access to the tool box. going to make some kind of removable center console i think... I'm sure theres lots of opinions on bench vs original style seats but I've got a young son and his mom and i like the idea of the three of us sitting across the bench.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5058_zpsnuxibvxg.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5058_zpsnuxibvxg.jpg.html)
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That looks good. What are you going to do for a cover?
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That looks good. What are you going to do for a cover?
i plan to stay sort of original with the cushions and covering. today i will finish the frame, use some 3/4" plywood for the back and bottom and then cut foam to shape and stretch some canvas over it and staple it to the plywood from the bottom. i have an idea to use a waterproof closed cell foam so when the seats get wet the foam doesn't soak up the water.
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well progress has been slower than i hoped. still waiting for some steering components. seat frames are done but not mounted.
completed frame with headrests
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5077_zpse2k9b7yp.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5077_zpse2k9b7yp.jpg.html)
removable passenger seat cushion with locking pin
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5076_zpsnr8rmsjh.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5076_zpsnr8rmsjh.jpg.html)
from the rear
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5079_zpsczmalo02.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5079_zpsczmalo02.jpg.html)
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finally got the frame fully mounted and wood rough cut. gonna paint the frame same green as the tub. the passenger seat bottom cushion and frame is not hinged, it just pulls out completely for access to the tool box. I'm thinking about 2" of a medium density foam for butt comfort with 1" of a higher density foam on top of it to prevent just squishing the softer foam flat. and on the back maybe just 2" of medium density foam. i was going to stretch canvas over the foam myself but I'm thinking more and more about getting it professionally done but in keeping with the budget build I'm unsure about that option, need to price it out. one thing that i know i will be splashing out cash on is seat bottom and back rest heaters, hear in the great white north seat heaters are a definite must.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5186_zpsoy4odhn2.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5186_zpsoy4odhn2.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5187_zpswridsbxj.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5187_zpswridsbxj.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5188_zps9lft0lya.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5188_zps9lft0lya.jpg.html)
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That looks great!
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seats finished! 3 layers of foam laminated together with slot between 1st and second layer for seat heating pad. 5/8 plywood, 2" medium density foam" for comfort, 1" high density foam for support, 3/8" closed cell blue foam for waterproof layer. its just a canvas tarpaulin cut up for cover.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5217_zpsbgxvbocd.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5217_zpsbgxvbocd.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5219_zps5p0xbisq.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5219_zps5p0xbisq.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5218_zpsrar9qpvr.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5218_zpsrar9qpvr.jpg.html)
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still need to cover headrests in the canvas. i have placed the steering column in and i can still slide in with stock steering wheel in original position. but as i am re-doing the whole steering set up i may change the column and steering wheel location slightly to give more room. i'd hate to have to change to a smaller steering wheel but it is an option if i have to.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5220_zpst3rqprok.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5220_zpst3rqprok.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5221_zpslmvrzu60.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5221_zpslmvrzu60.jpg.html)
still 6" above my head to bikini top
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5222_zpsm2twvlud.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5222_zpsm2twvlud.jpg.html)
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finally got started on the steering. pulled the whole front off and apart, kinda needed it apart anyway so i can finish the half done paint job. the rad support/cross member was severely cracked on each side where it was welded to the frame. to clear the new steering shaft i figured easier to just remove that cross member anyway and replace it with something different after i finish the steering setup. so i got a complete steering setup for free (still within budget) by trading some other jeep parts. its from a Jeep YJ 4 cylinder with power steering. yes i said power steering. just gonna give it a try, its been done before but to be honest not sure how well it will work on the little 65 year old 4 cylinder. so I'm boxing the front of the frame, mounting a yj steering box to the inside of drivers side frame right behind the bumper that I'm still building and will make a bracket for the pump that will mount on the engine. anyway enough talk...
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5392_zpsrmpgf30e.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5392_zpsrmpgf30e.jpg.html)
i took a bunch of measurements before chopping this out so i can get it square and true again later
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5393_zpsiudzcfty.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5393_zpsiudzcfty.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5395_zpszz6luvob.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5395_zpszz6luvob.jpg.html)
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templating for the boxing plate
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5396_zpsbtqtqqjv.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5396_zpsbtqtqqjv.jpg.html)
trial fit. it will fit just inside the factory channel so i can get a good weld on all sides. i will just stitch weld it in i think as the factory boxing plates further back are only stitched and i don't want to make this front section of the frame that much more rigid than the rest of the frame or it may be inviting future cracking. i will put a diamond shaped 1/8" doubler plate over that vertical seam and will probably extend the doubler to where the replacement cross member will be.� i will also be relocating that hard-to flexible-to hard front axle brake line and mount as its right in the path for the steering shaft.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5397_zpsd9paodeh.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5397_zpsd9paodeh.jpg.html)
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well i picked up the steering parts late in the day and couldn't wait until tomorrow to see how things fit. so i just went out to the shop and mocked it up.
this is the box as far forward as it can go and dead level.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5403_zpsoqvo4y2o.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5403_zpsoqvo4y2o.jpg.html)
in this position the front leaf hanger blocks one of the box mounting holes so will probably slide it rearward a bit.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5404_zpsauuvqsqm.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5404_zpsauuvqsqm.jpg.html)
with the current drop pitman arm the drag link is level with what will be the height of the tie rod but i see possible interference issues at full left turn with left side leaf compressed. so i plan to run a straight pitman arm to hopefully avoid that.
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drag link will be 2" higher than this on the straight pitman arm which won't be a real issue i think. i have to source a tie rod yet and due to the fact that these knuckles only have one rod end hole ill run the tie rod from knuckle to knuckle and the drag link will attach as close to the passenger side knuckle as i can get it to work.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5400_zpsciwgdtxc.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5400_zpsciwgdtxc.jpg.html)
here you can see the steering shaft and how the brake line bracket interferes. ill move that bracket and i think i also need to clearance a small piece on the engine mount. the factory YJ shaft looks like it will be perfect length otherwise and with the box mounted close to current position the angles on the shaft u-joints will be minimal.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5402_zps3othibpm.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5402_zps3othibpm.jpg.html)
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ok so today i started welding stuff up. theres a pic below for you experts...and i use that term loosely ;)... to review and give me some feedback please. so heres my concerns; i only stitch welded the boxing plate because the factory boxing plates that run from where i left off down under the motor and transmission are also just stitched. in a lot of the reading I've done the CJ's flexibility comes a lot from the frame. so by boxing it in and welding it fully i would be eliminating a lot of the frame flex and probably adding a rigid area that would or could induce future cracking. now my thoughts also are that the original steering bell crank came off the large cross member i removed (i will be replacing it with something equally as strong later) but that cross member was badly cracked at the welds where it met the frame rails. I'm figuring the reason for cracking is from stresses put on it from the bell crank during turning. i am now going to be mounting the steering box on drivers side frame rail so the steering stresses will be there. so should i not worry about losing possible flexibility and weld it fully because i need that piece of frame to be very rigid for steering box mounting? the box I'm using has 4 mounting bolts and i will be capturing all of them, 2 above the frame and 2 below. i may also run a steering box brace across to the passenger side frame rail. i do plan to use a doubler plate over the vertical seam where my boxing plate meets the factory one. i used 3/16 material for the boxing plates and will use 1/8 for the doubler plates.
long story short... should i fully weld these boxing plates in or leave as is?
your thoughts.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5407_zpsw6xkt6ee.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5407_zpsw6xkt6ee.jpg.html)
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I can't really offer an informed opinion on boxing the frame, though I have read similar discussions about the need for the frame to flex. Out in front on these horns, I don't think you need to worry much about the need for flex. In fact, Willys M38s were boxed from the factory.
I must say, those are some nice looking welds. Especially when comparing them to the originals on a Willys. Those originals make me think I'm a good welder. ;D
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well after lots of reading and talking to guys who know more than me i decided to stay with the stitched welds. i also added doubler plates to the vertical joint between my new plate and the old. i cut and test fit the new crossmember. this new cross member is 1.5" DOM heavy wall tubing, should be plenty strong. it is in exactly the same place as the original CM but as it doesn't have the upward bend i will have to make brackets for the grill support. with the steering box in location the steering shaft clears the new CM just fine due to it's reduced size.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5409-1_zps9tbx4tms.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5409-1_zps9tbx4tms.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5410_zpsocemeck7.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5410_zpsocemeck7.jpg.html)
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so i ended up rebuilding a buddies Grand Cherokee suspension for the last 5 days...no fun! who ever thought putting a 7" lift in a unibody vehicle was a good idea was a great comedian. anyway we got it done and now i got my shop back to myself so the Willys is center stage again.
had to make a mounting plate for the steering box with some offsets on it so i would have something flat to weld/bolt things up to. one of the box mounting bolts goes through the leaf hanger and is sleeved to prevent crushing when tightening the bolt. i still need to gusset or connect the one sleeve to the lower side of the frame as you will see in the pics.
flat bracket
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5441_zpsuipmjql0.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5441_zpsuipmjql0.jpg.html)
welded in, i'm pointing at the sleeved hole through leaf hanger. you can see the sleeve lower right that i still need to make a bracket to capture.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5445_zpsvhfr6vxy.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5445_zpsvhfr6vxy.jpg.html)
steering box bolted in, lots of room to bumper and just enough space for steering shaft to clear the cross member that isn't there.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5449_zps2yheuaxr.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5449_zps2yheuaxr.jpg.html)
i have cut a small piece out of the drivers side motor mount for steering shaft clearance and i had to move the front axle brake hardline mount. i will end up cutting a bit out of the grill for power steering hose clearance but i won't know how much until its all installed.
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so todays progress was slow but worthwhile. i took a close look at tie rod and drag link setup and i plan to do as many others have and use heim joints. on the passenger side i'll have drag link on top and tie rod on the bottom both connected by one bolt. i'll do my best to be safe and overkill strong, ill be using chromoly heims with 3/4 shank on 3/4 bolt and DOM tube for the shafting with as little shank exposed as possible. ill use castle nuts and safety washers to ensure even if the helm comes apart it can't come off the bolt. the vertical separation with existing pitman arm is not enough so i went to local pick n' pull and grabbed a straight arm from a 1998 Astro Van so that will help. i then looked at the steering column and height of steering wheel. I'm gonna try and get it at a bit more comfortable position than it was, i am just waiting to finalize that until i make sure my steering shaft will work, the one i got doesn't seem to 'slip' in the middle and i don't like that so gonna source another one.
from passenger side showing horizontal separation of tie rod and drag link
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5457_zpsr3gtksjt.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5457_zpsr3gtksjt.jpg.html)
from front showing vertical separation of tie rod and drag link
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5458_zpsxzvoqtv7.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5458_zpsxzvoqtv7.jpg.html)
positioning steering column and wheel
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5459_zpswphhvjno.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5459_zpswphhvjno.jpg.html)
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HAPPY EASTER!
after the egg hunt and brunch it will be time to make some steering progress. picked up 2 more steering shafts from a friend, they are from a grand cherokee and both short but they have the right ends and the slip in one works so i will make 1 out of the 3 that i have and i can instal the pitman arm and then move forward with steering column.
pitman arm 98 astro van 2wd
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_8489_zpsbmrdrpei.jpeg) (http://s963.photobucket.com/user/buggysale/media/IMG_8489_zpsbmrdrpei.jpeg.html)
grand cherokee steering shafts
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_1251_zps7mehqsg6.jpeg) (http://s963.photobucket.com/user/buggysale/media/IMG_1251_zps7mehqsg6.jpeg.html)
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i made up a steering shaft from the 3 i had. wanted 33.5" and 4" slip.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5480_zps9e9cmkyo.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5480_zps9e9cmkyo.jpg.html)
to be sure that the shaft doesn't drop off the column i drilled and tapped in a set screw and put a groove in the column.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5496_zpssmzrmxxt.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5496_zpssmzrmxxt.jpg.html)
and this flat side stops the column from turning inside the shaft
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5497_zpsfijhzxyf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5497_zpsfijhzxyf.jpg.html)
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the inside floor plate. the top of the column has a factory bearing and i had a bushing machined that goes inside the bottom of the column to hold the internal shaft.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5490_zpsd7krtpg5.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5490_zpsd7krtpg5.jpg.html)
underside floor plate
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5489_zpsyhrsisle.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5489_zpsyhrsisle.jpg.html)
fully installed, you can see the chunk i cut out of the motor mount. i have test fit the cross member and it just clears the joint where it meats the steering box.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5487_zps68qj1zgh.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5487_zps68qj1zgh.jpg.html)
all the parts are getting paint and ready for instal but now its time to build the power steering pump bracket.
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progress today, i replaced all the fuel lines and rerouted things to make room for the coming power steering pump, they were a mess of old copper lines anyway. i also re-ran the hard brake line to the front axle since i had to relocate the frame bracket that holds the brake lines. got the cross member welded back in and cleaned up and painted the frame. tomorrow is pump bracket and assembly. i also finally made the bracket to capture the 4th steering box mounting bolt.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5499_zpstslp9wax.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5499_zpstslp9wax.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5500_zpspxu7zgb8.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5500_zpspxu7zgb8.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5503_zpskfmnmuyi.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5503_zpskfmnmuyi.jpg.html)
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ok so today was a good day. built the pump bracket and managed to route hoses. if i had mounted the steering box 1/4" further ahead i would not have had to cut the grill for clearance...as it is i had to cut it a little bit. anyway i'm having photo load issues but heres the pump bracket, I'm super happy how it turned out but i can't take credit, i found several pics online of others that did it and i copied.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5511_zpskat3g1ky.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5511_zpskat3g1ky.jpg.html)
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fixed the upload problem, more pics.
this is what i cut out of the grill
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_1222_zpsu3bycp6b.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_1222_zpsu3bycp6b.jpg.html)
view from front of engine
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_1220_zpsbatvwtyd.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_1220_zpsbatvwtyd.jpg.html)
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more progress but its slow. today i got the grill painted so i can instal it and mount the rad to actually run this engine to cycle the power steering. didn't get the grill mounts finished so didn't run it yet :( the materials for tie rod and drag link arrived today, woohoo! finalized the hoses for the power steering, happy with how they worked out. got new bump stops put into the front as well.
painted grill installed, you can see the hoses sneaking around the lower drivers side grill.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5520_zpsxhwmi6w8.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5520_zpsxhwmi6w8.jpg.html)
new bump stops
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5516_zpsbe9ggdhr.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5516_zpsbe9ggdhr.jpg.html)
tie rod and drag link installed
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5522_zpskudcoi2w.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5522_zpskudcoi2w.jpg.html)
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this shows the new shiny parts. 5/8 shank with 5/8 hole chromoly heims with 1.5" x 1/4" wall DOM tube. this should be beefy enough for a 2000lb Willys. i drilled out the pitman arm and knuckles for 5/8 hole, that was the size of the large end of the taper for tie rods so thats why the decision to go with 5/8 heims. tomorrow i'll weld the bungs into the tube and mount the rad and fire this thing up... i may actually have steering tomorrow ;D
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5524_zpsmb4o4nsf.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5524_zpsmb4o4nsf.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5527_zpsuafcf9pb.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5527_zpsuafcf9pb.jpg.html)
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well not a lot of pics today, too busy wrenching i guess. welded up the tie rod and drag link tube inserts and added the three factory location grill supports to the new cross member. then tried to mount the rad... oops, why didn't one of you remember to tell me to check rad clearance to the steering shaft?� >:( so the drivers lower corner hit the new steering shaft not far after it comes off the steering box. i was able to just raise the rad about 3/4" and it cleared but now i'll have to trim the shroud to get it to clear the fan. i can still close the hood too, BONUS! then filled the rad, filled power steer pump, cleaned out the fuel pump and checked all other fluids then turn the key. after a few minutes of tracking down an incorrect wire to the started solenoid she fired up. cycled the steering and topped up fluids and she purrrrrs like a John Deere. fit the new front bumper and its great but the old Warn M8000 winch doesn't fit in the remaining space. i think i'll wait until budget permits and pick up a modern narrower winch instead of re-fabbing the whole bumper plan. in the video it sounds like a little diesel, anyone else hear that? well the muffler is full of holes and theres no tail pipe so hopefully once I get to doing the exhaust and put the hood/fenders back on the sound will improve. on with the pics...
the remaining winch gap thats too small...
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5531_zpsgojsoa61.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5531_zpsgojsoa61.jpg.html)
video of her running and steering. theres some added noise when i steer that is just from the loose column since i didn't fully bolt it in as I'm waiting to paint the interior before completing instal.
<iframe width="560" height="315" src="https://www.youtube.com/embed/HmPEXPh327o" frameborder="0" allowfullscreen></iframe>
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finished cleaning up and painting tie rod/drag link and got them installed permanently. did the re-engineering and re-fab work to the bumper, even got it painted and installed. i have decided to narrow the Warn M8000 winch I have instead of try to buy of find another one (budget build). also installed and wired up the lights in the grill. on with pics...
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5534-3_zpsyscgysqm.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5534-3_zpsyscgysqm.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5535-2_zps5fd04p4u.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5535-2_zps5fd04p4u.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5533-3_zpsppxuw6we.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5533-3_zpsppxuw6we.jpg.html)
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the finished front end. i have since swapped in correct length bolts and tightened the pitman arm nut. now if only the rest of the jeep was painted...
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5543-1_zpsntgrycqn.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5543-1_zpsntgrycqn.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5541-3_zpsqhifhm17.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5541-3_zpsqhifhm17.jpg.html)
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Moving right along... Dang looks good
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Definitely looking good.
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Will the winch fit if you offset it?
Skip
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Will the winch fit if you offset it?
Skip
no the remaining gap from passenger frame rail to steering box is 20", the Warn M8000 i have is 21". i will be doing this modification today, it is fairly easy to narrow the drum on these winches so i plan to take 4" out of it and then it will be 17" and fit just fine. the drum originally is 9" and is rated to hold 100' of wire rope and i have synthetic rope for mine so i should still fit about 60' of 3/8" rope on the drum and i carry a 50' extension so that should be plenty of length... not to mention they look cool when they are narrowed ;D
and in other news, i ran the engine a bit yesterday and checked things over. the 'new to me' power steering pump has a slight leak. seams to be from the actual body and not a hose connection...bummer. will do more looking into that. the coolant filter i put into the top rad hose is definitely doing its job and needs to be cleaned out before much more running as its completely full, i put it in to prevent rust/scale of sitting for 35 years from getting into my very costly re-cored rad and I'm very happy it appears to be doing its job. and finally someone asked about oil pressure and so i monitored that from cold start up until warm. 40psi at cold start up, drops down to 25psi at idle when warm and can get as high as 60psi when revved up. i hope that sounds alright.
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today i didn't have alot of time but i started the hood. at first i was planning to just grind down the old repairs that are lead, brass and weld... and then re-do the welds and maybe smear on some bondo and hit it with paint but after I started the grinding i realized how far gone the hood was. so after some quick measurements and cutting heres what we have left. i had to go grab my bead roller from a buddies house this evening so tomorrow I'll flange both sides of the new piece and weld it in.
the old piece i cut out. you can see some of the brass. the lead on the centre seam was almost 1/4" thick
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5561_zpsutv1et3h.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5561_zpsutv1et3h.jpg.html)
whats left of the original hood, i left the back end hat channel intact and the hinge.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5562_zpslxqrvjei.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5562_zpslxqrvjei.jpg.html)
and finally the new piece, i will also weld a solid 3/16 round bar across the front to replicate the rolled front edge.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5563_zpsj6stex35.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5563_zpsj6stex35.jpg.html)
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busy again today. finished hood, narrowed winch, started body work on cowel that turns out to be full of bondo >:(
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5571_zpsjvcbu6xd.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5571_zpsjvcbu6xd.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5572_zpsr9tlarwc.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5572_zpsr9tlarwc.jpg.html)
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everything worked out great, very happy with how it came out. i left some of the imperfections as the rest of the Willys is slightly less than perfect...just slightly ;)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5574_zpsuob6mi0i.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5574_zpsuob6mi0i.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5573_zpsv08i6fek.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5573_zpsv08i6fek.jpg.html)
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heres the winch prior to cutting. you can see the 4 pieces that had to be shortened. the side plate on the drum had to be moved so it was carefully cut off and welded back on after shortening.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5532_zps2a7sovd3.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5532_zps2a7sovd3.jpg.html)
finished product. just needs clean up and paint. 4" narrower.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5577_zpsfbgem3d6.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5577_zpsfbgem3d6.jpg.html)
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well i managed to paint the rest of the tub and a lot of small parts that i'll need for assembly.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5580_zpspkcrlty8.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5580_zpspkcrlty8.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5581_zpsebehpkzu.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5581_zpsebehpkzu.jpg.html)
i also found a used set of 5, 6.50 x 16 michelin bias ply tires. i like them and the price is right. need to organize a ride for the tires from a town about 500km away.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5583_zpswbquv8xs.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5583_zpswbquv8xs.jpg.html)
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And more sanding/painting. I'd rather do anything else... Just have the front fenders left to do and assembly. I got my tires arriving tomorrow too. Should be on the trail in a few days[ch128513]
(http://i963.photobucket.com/albums/ae114/buggysale/Mobile%20Uploads/image_zpstplhpbwl.jpeg) (http://s963.photobucket.com/user/buggysale/media/Mobile%20Uploads/image_zpstplhpbwl.jpeg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/Mobile%20Uploads/image_zpsyke22s7w.jpeg) (http://s963.photobucket.com/user/buggysale/media/Mobile%20Uploads/image_zpsyke22s7w.jpeg.html)
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Wow, its looking really good!
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ok, today was a long day. had some family obligations but i also had Jeep progress to make. so in the morning i sanded, welded, repaired and painted the remaining front fenders. came back in the late afternoon and mounted fenders, mounted hood, windshield frame, installed many of the accessory parts and pieces, made some dash progress, swapped out the tires...etc. so here she sits! i tried the power steering with weight sitting on the wheels and it works great. engine is running good. theres a few small things to tidy up but she should be street and trail ready tomorrow.
still need to sandblast and paint the winch body, going to swap the tires from the rims they are on (chevy tracker 7") to the original Willys 5", finish VHF instal...and i'm sure I will come up with many other things to do.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5624_zpsyuzy3qgu.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5624_zpsyuzy3qgu.jpg.html)
the tires were sold to me as 30" but at 16 psi measure out closer to 28". :( very interesting and fortunate that the tracker wheels bolt up.
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its ALIVE!!!!
moved under its own power for the first time since november 2015. I'm not going to say finished but its a lot closer than it has been in a long while. couldn't resist 'flexing' her out on the front yard.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5634_zps95kzylsr.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5634_zps95kzylsr.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5635_zpsnclhrtkr.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5635_zpsnclhrtkr.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5636_zpsyn6tfdtb.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5636_zpsyn6tfdtb.jpg.html)
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well i put insurance on it today. needed to get some in town miles on her before i try to put some offroad miles on her. had to bleed the brakes since i changed the hard line to the front axle and bolt down the seat completely but other than that she was good to go. filled the fuel tank for $25.00 and drove it around town most of the day. got lots of thumbs up and waves around town. a couple old timers wanted to chat about their military time driving Willys... i didn't have the heart to say that this particular jeep and model never saw war/military service, i must have gotten the green color at least close to olive drab. i am looking forward to the small jobs i have to do to get her more trail worthy like building a rear bumper and stronger diff covers. it will never be finished i suppose.
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i have been doing a bit of painting lately... maybe u noticed. so i figured I'm not bad at masking stuff off, couldn't have been more wrong. yesterday i decided it was time to clean up and finish the narrowed winch. took it to a buddies who has a glass bead blaster. cleaned it all off and brought it home for paint. after paint and assembly i tried to turn the drum...no go. seams that no matter how well you think you masked off the gear box side of a winch the pressurized glass powder will get past the tape, mix with the grease and make an abrasive paste that will not allow the winch to turn. so complete disassembly and clean up ensued and re-paint and re-assemble. finally mounted it this evening.
cleaned, greased and awaiting final assembly
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5658_zpssf9ny7xt.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5658_zpssf9ny7xt.jpg.html)
installed
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5659_zpsv7bcau62.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5659_zpsv7bcau62.jpg.html)
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also i have been working on the rear diff cover. i asked around and can't find a beefier one on the market (or any one for that matter) and so what the heck, lets make one. so ill just let the pics do the talking. 1/4" base flange and 1/8" for the rest of it. haven't done the final welding yet but i plan that for the morning, supposed to take the Willys camping for the weekend and kinda need some diff fluid in it i figure.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5653_zpsv2hgrqej.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5653_zpsv2hgrqej.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5661_zps5joaqjdq.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5661_zps5joaqjdq.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5664_zpsjjaou5dy.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5664_zpsjjaou5dy.jpg.html)
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(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5665_zpsgcb52fms.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5665_zpsgcb52fms.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5666_zps1miw5qk0.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5666_zps1miw5qk0.jpg.html)
it looks a lot deeper than the original but its only .5 inch deeper. it will hold a lot more fluid due to shape. still gotta add fill plug and do the final welding without warping that base flange.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5667_zpsrqvpotpd.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5667_zpsrqvpotpd.jpg.html)
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finished up the diff cover. used the fill plug from the original cover. mounted it and filled it with fluid and took it on a road trip to camp overnight. drove her about 100km (60miles) roundtrip on highway and 50km through the bush on gravel road and then some easy trails. she did well, seems to have a slight t-case output leak but everything else functioned well. using GPS i got her to 97kph on the highway or about 58mph. tracks nice and straight and works good but i can say i don't think i plan many long on road trips. next time i'll trailer it.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5674_zpswyxesxzq.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5674_zpswyxesxzq.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5673_zpsnmmcsry4.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5673_zpsnmmcsry4.jpg.html)
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painted the wheels today, the silver just wasn't doing it for me. who ever on here posted that "card trick", thank you. so easy! and here is the diff cover installed. still need to sort out the brake line brackets.
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5702_zpsjiuvu8pv.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5702_zpsjiuvu8pv.jpg.html)
(http://i963.photobucket.com/albums/ae114/buggysale/IMG_5703_zpshqid5jrb.jpg) (http://s963.photobucket.com/user/buggysale/media/IMG_5703_zpshqid5jrb.jpg.html)
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Nice work! Keep us updated.
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Just wanted to post some "finished" pics... ok ok, i know its not finished. working on small things lately. needs speedo cable, fuel tank sender, hand throttle needs some fine tuning...etc
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It looks great. Nice work.
I wish I could put one together that fast.
Tim
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Pretty amazing project for something that started 5 months ago. Some of your custom work is stuff I wouldn't be able to do in a lifetime.
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Well I know I've been slacking. Not much happened to the little Willys lately. Today I finally replaced the floor in the tool box, it's been bugging me that I had left it undone so I got to it. Not a lot of pics but I cut out the rust, fit new pieces that had to go through the opening so needed three, welded them in then the old seam sealer trick and tomorrow is paint. I did bend up the edges on the rear and out side edges so it could be welded up the sides but unable to flange it due to fitment so its butt welded.
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The most expensive part of this build was the re-cored rad at $500 so I put in a coolant filter after the thermostat in the top hose to prevent any 30 year old gunk getting into it. Well today I cleared it out... I'm glad I put it in.
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Wow . . . yeah that might have clogged up a few cores of radiator. :o :)
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Where did you find that filter? I was looking for one a few years ago and couldn't find one anywhere.
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Where did you find that filter?� I was looking for one a few years ago and couldn't find one anywhere.
I ordered from eBay. Just search 'gano filters'. Make sure you check ID of your hose, there's a few sizes.
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yet another example of the quality of person drawn to flatties... after i posted that i was in need of a speedo cable one of our amazing members took it upon himself to send me one. he said he had a spare and if i needed it i could have it. he wouldn't take any payment even for shipping. THANK YOU!!! it arrived in the mail a week later, last night I got the new speedo cable in and for the first time in i guess at least 35 years she has a working speedo. i pulled the old cable and it is pretty obvious why it wasn't working. took it for a drive and compared it to my GPS, speedo said 40MPH and GPS said 35. i think my tires are a bit bigger than stock so should that make up for the difference of 5mph?
also a pic of the completed painted tool box floor.
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Well I met up with Chuck, he's on the 2A page. Forget his username there but in July he's planning a flat fender get together near where I live. So we went to pre-run some trails and really it was the ol' girls first actual off-road shake down. Did great! Met good guys and ran some nice trails with amazing scenery. Looking forward to the run July 17-24. Camping on site at Chucks place and I just live 45km away. Probably camp as I plan a few after trail beers :D
On with the pics