Building CJ3A seat springs

[stony]

OK, I should know better but have decided to build a set of 3A seat springs, since no one sells them.  I have enough of my rusty old spring for a pattern.  First thing:  order the parts and tools.  Came today.  I continue this as it moves along.

[Bob W]

I can't wait to follow along as you build the springs! I rebuilt the springs in one of my Jeeps from several sets of damaged original ones.

[stony]

Going to start out with what I have.� Comparing the stuff have to the original springs.� Start with the back springs.� I am lucky that I have a pretty complete back, and can see how it was constructed.� The zig zag springs that I got look about right.� Here is a photo of the back and an individual spring section.� I included my $55 Spring benders.� At first I thought �man these things are expensive�, used them to straighten out a section of spring and � man these things are sweet� .� Anyway here we go!

[stony]

Piece of cake!� One down, 49 to go.� My new springs are a tiny bit shorter than the originals, but just a matter of compensating by adding an extral zig or zag here and there.� Will probably use edge wire for the back side and springs ( if I can figure how to make them) for the face.

[stony]

If you are wondering what the seat springs look like here is one next to a back spring.  The vary a bit from 3 to 4 zigs but should be easy to duplicate.  FYY I THINK CJ2A seat bottoms are more like the 3A backs, but not sure.  Mine are 4� high.

[stony]

OK, Made my first big mistake, I got the wrong Spring . Correct gauge (11) but the wrong shape, too compact and stiff.� Ordered the right stuff and just have to wait till it comes in.� On the bright side, got some practice in and know (kinda) what I am doing.� This does give me some time to work on my new (1953) Singer 201-2 sewing machine so I can do covers and a top.� Good thing this is all tax deductible, cuz the weather is not cooperating and I�m not getting any planting done.

[stony]

OK, so the right spring came today.� You can see that it matches the original pretty well, so good to go there.� I made a couple of springs and they came out pretty well.� I think they will duplicate the feel of the original fairly closely.� I figured out how to bend them, problem is figuring how to do it quickly.� Will need 25 per bottom.� I measured mine at 4� high, do you all think that is correct?

[Bob W]

I measured a well used original spring and it is 4" tall.

[stony]

OK, A little progress report:� I have figured out how to make a perfect (almost[ch128540]) replica of a CJ3A seat base spring, and I think I can do it fairly quickly, so I am pretty sure that I can reproduce the base springs pretty accurately for anyone redoing there seats they are the correct height (4�) and length, they probably will not be cheap, but I should be able to figure this out in a few weeks.� Also for anyone that is looking to repair there old seats I don�t see any reason that I shouldn�t be able to provide individual springs to replace broken ones, we�ll see.� Anyway for now here is what I have:

OK I went ahead and made a set of springs, need 5 sets for a bottom.  It is interesting that the lower springs are 1 loop shorter than the uppers, so there is a bit of an overhang in the back.

[squidtone]

NICE

[stony]

OK, have not posted in a while, but making progress at last.  Bending and putting the springs together turned out to be a real PATA, so I kinda let it drop for a while to figure out how to do it.  The reproduction CJ2A spring sets that Walcks sells were put together with three prong clips so I tried that and it did not turn out well.  So I went back and looked at how the originals were put together with coil springs wound around the seat springs.  At first it looked like a complicated nightmare, after studying it while a while it dawned on me that it was really pretty simple.  I gave it a try and was surprised how simple it is.  I have put together a jig to hold the springs when I tie them together and should get a back done pretty soon.  My goal is to be able to make some seat spring sets to sell, but that is still a ways off.  I however have gotten better at bending springs and making binding coils (that what I call them) so if you need to replace some broken parts I can probably make them for you.  Anyway here is where I am.

[stony]

So!  Got the seat bottom done.  Came out pretty well.

[1955CJ-5]

Really nice!

I have foam inserts in my 3a..the thick ones....a little stiff to say the least.

The CJ-5 still has its original springs...a little saggy but a much better ride!

Nice work....looks a little to complicated for me...

[stony]

So, it rained today, so got the old Singer out and tried my hand at upholstery, sewed a couple of seat bottom covers.� Made a few mistakes and my stitch lines are not perfect, but not bad for a first try� .� The key is go S.L.O.W a lot of turning the balance wheel by hand on the corners.� Red Naugahyde Universal.

[stony]

So, after a few more mistakes, mainly making the boxing (sides) too short (almost) I got one seat together.  The new springs are 4� high and I used the old cover as a pattern, well after sewing in the drawstring I had very little room for padding.  The originals didn�t have much either, so had to change my plans of using a couple of inches of foam.  I wound up using a old floor mat to cover the springs and then 1/2 inch hard foam and several layers of cotton batting.  Was a little worried that it would be too stiff.  Put it on the drivers side seat and went for a drive.  Turned out that it is pretty comfortable, firm but some spring to it, like it a lot.  It wound up looking pretty good too.  Still need to do the backs but so far so good.  Anyway here it is: