Taking Forever...the Willys Build

[McCracken]

Going out today to be blasted.

 

[McCracken]

Well, the cab came back and I promptly ordered new metal.

 

[XJsavage]

That's... Not.... Um. Terrible.

 

[McCracken]

Honestly after I cut that shit out and drop a few panels in it'll look 100 times better. Most of the damage was around the rockers and supports.

I'm working on getting a carport setup to work in. As soon as I do I hope to speed this build up.

 

[McCracken]

Ok, sorry the updates have been slow (maybe you understand the title now). I've still not got the shed worked out and all I've been doing is hunting for an LS swap. However, I did do something yesterday. I did a little minor body repair. At the firewall on each side of the truck is where the fenders bolt up (duh) but in this case it appears that on the passenger side there may have been a little fender bender back in the day. As you can see on the driver's side the sheet metal is relatively straight.

On the other side however it's a little off. So this is the side I tried to work on.

I didn't get many pics mainly because I don't need a bunch of people laughing at my body work style. Anyway, I really did try and finesse this piece back into shape. I took clamps and 2x4s and tried to coax the sheet metal back into place. I even took a small propane torch to try and heat the metal as the clamps provided the pulling force. Needless to say it didn't budge and I ended up melting/burning the powder coat on the cab So as with most of my builds I brought out my most important tool... the 3 lb sledge.

If you don't have one of these I feel sorry for you son because out of 99 Jeep problems force ain't one. So without further ado I climbed into the cab and with one well placed strike, this was the result...

So I wasted an hour using "finesse" techniques only to solve my issue in less than 30 seconds with the correct tool. So keep that in mind folks. This also applies to crawling.

Lastly, I worked on fabbing up a template to replace the cab mounts. I'll start on those next. This is what I'm working with so on my next update I'll show you what I did to fix it.

 

[McCracken]

wow. so yeah.. it's been a while. Like damn near 2 1/2 years. Ok, to bring everyone up to speed:

1) Bought a carport so I'd have a place to work
2) Bought a truck from the company I worked for that had a 4.8 LS

3) Got the LS out

4) Collected a set of axles (Grand Waggy) and some wheels

5) Found an AX15 and a D300
6) Bought the needed adapter off of here
7) Bought an Isuzu dana 44 with discs and a limited slip
8) Collected another front Waggy axle. This time with the correct drop.

 

[McCracken]

9) Made a mock frame so I could see if the truck cab would fit the dimensions before I cut my steel up and made a major mistake

10) Took a new job in East TN
11) Moved some of my junk up here.
12) Asked questions about wiring the new-to-me shop and wired it up

13) Actually worked on something related to the truck in the new shop...

 

[McCracken]

So now that you know what I've been up to here's what I worked on today.

This is the Isuzu dana 44. 4.30 geared, disc brakes, 6-lug and limited slip. Good stuff. I'll need to regear it but for now I want to clean it up and get some new perches for the 63" chevy springs I acquired through craigslist (whoops, I forgot to mention that acquisition). Probably because I honestly thought I would have to kill someone when I went to get them and I've tried to block it out of my mind. On with the tear down...

The chunk looks good on the inside and the oil was clean. I took off everything that I could. Brake lines, rotors, calipers and e-brake hardware. Next, I took the axle shafts out. Damn am I spoiled. I've been playing with one tons for so long I forgot how to take these things apart. Thanks to my inside source I got them out. If you want to know how you have to take every bolt out of the backing plate. There are four. My old Cherokee 44 had four bolts too but you could tell it held the bearing in. This BS was the entire assembly. The bearing retainer is made into the backing plate / dust cover.

Next came out the gas axe and I took the perches off.

Then I ground the toob smooth.

and that's it for now. I did primer the tubes so I can go back later and set the perches where I want and not ruin the sweet paintjob I have planned.

 

[McCracken]

I started in on the front axle but damn if I didn't forget my hub socket. Do I have the one for my 60? Oh, but of course!! It's back in NC, so as soon as I head back that way I'll get it. Or, I'll get impatient and go rent one from O'reilly's or something. Regardless, I will tear it down and do the same thing as I did to the Isuzu. It had been in the field a long time so it'll need new everything. Rotors, caliper, u-joints, ball joints, blah blah blah. Maybe I'll start to work on the frame...

 

[Jody Treadway]

It's fitting that you are the proud owner of an import JK Dana 44.
Calling it an Isuzu rear is like calling @Loganwayne "sexually confused"

We know what it really is.

 

[McCracken]

But, but, butt

 

[drkelly]

I love the wood frame. That is something I would do too. This is a cool build thread.

 

[McCracken]

I love the wood frame. That is something I would do too. This is a cool build thread.

IMO 2x4s are cheap and I think everyone has a small piece of plywood laying around. It worked though so I'll consider it a success.

 

[Scooter402]

This thing is sexy...I love Willys trucks. I've apparently missed this one while digging through the build threads. I'll be watching for sure! Maybe we'll have to see who's takes longer to finish, yours or mine.

 

[Loganwayne]

Your picture of pulling the cab/motor does not show the sketchyness of what was happening. Where’s the pictures of us moving the motor and everything from the move. It sets the right tone for how this Willis is gonna get built


Sent from my iPhone using Tapatalk

 

[McCracken]

Your picture of pulling the cab/motor does not show the sketchyness of what was happening. Where’s the pictures of us moving the motor and everything from the move. It sets the right tone for how this Willis is gonna get built


Sent from my iPhone using Tapatalk

I tried to find those but I can't find them. Actually, now that I think about it I think it could be in the Random Picture thread.

Edit: Found it

LS in a wagon

 

[Creekin]

LS in a wagon?

That is going to be one fast wagon!

 

[McCracken]

OK, day two in the books. Started taking apart the front end today. Much like the rear I'm going to be buying some replacement parts. So yesterday I said I might wait till I travel back to NC to get the spindle socket.... yeah I went and bought one. BTW, if you want to know the size for a narrow track d44 spindle nut it is 2 1/4".

I ended up buying two and plan to take the other back tomorrow. Continuing on... I took the rotor and hub assembly off after taking care of the spindle nut. This little guy was here yesterday in the same spot. It must be so cold he's like "fuggit, I ain't moving".

and yes, he's alive. So I took it off and found this

So I did this

to hell with spiders and bugs. The end of the axle shaft got me thinking something wasn't right inside the spindle. I was right, I found this.

The spindle bearing is boozed and will need to be replaced.

 

[Jody Treadway]

That is the most perfect use of the word "boozed" ever.

 

[McCracken]

I took the axle shaft assembly out. I see why people like them. These little guys are so cute I laid the toothpicks aside and carried on. Next I took the top castle nut off and the inside ball joint nut. I used the same propane torch to heat the nut a little and it came right off with no issues. Then...

I then got to the other side. Rinse and repeat.

After taking both sides apart, I noticed something missing...

I then decided to check the chunk out. Everything looks good to me. Unfortunately, it did have a little water in there. The breather was missing from the axle and I think a little rain got in there while riding around in the back of the truck.

I then took time to take a scrape and clean as much of the built up oil and dirt from the axle. I plan to pressure wash them but I've got to wait till it warms up a little. Next, just like the rear, I cut the one underside spring perch. I treid something new this time. I bought a port-a-band a while back and thought I'd give it a try since the perch is only welded on the outside edge.

After this, I grabbed the torch and laid hell to it. I tried to be delicate but I ended up getting into the tube a little. I also cut too deep with the port-a-band. The only thing I knew to do was take the grinder and dig out the cut.

After this I welded up the trench and smoothed it over with a flap disc.

 

[McCracken]

Last thing I did was work on the cast spring perch. I want to smooth the edges out. I took the port-a-band and cut off a chunk.

I'm not sure what happened but I cut some more and forgot to take pics I also smoothed out the cuts and rounded it the best I could. It didn't turn out as good as I hoped. Maybe that's why I didn't take pics. I'll snap one tomorrow and update this.

So that's it. I plan to pop the ball joints out next and get them ready for new ones. I know why I title this build the way I did but I think it'll take forever now because of all the parts I'm going to have to buy. Being a broke ass is no fun.

Edit: Here's where I cut and smoothed that perch mount.

 

[XJsavage]

I'm glad this build is still going. All these ideas on what to do with this extra 5.3 I'm about to have sitting around is making my beer buzz wear off though.

Carry on.

 

[BigSouth]

Whatever you do, DON’T make a spreadsheet to add up what it’s all gonna cost. I still cry a little when I look at all the parts I do own vs all the ones I still need to buy.

 

[paradisePWoffrd]

There are a few places that make UHMW bushings to replace those spindle bearings. I prefer them, as you dont have to deal with the needle bearings.

 

[McCracken]

There are a few places that make UHMW bushings to replace those spindle bearings. I prefer them, as you dont have to deal with the needle bearings.

I'm not familiar with those. I've always had the bearings.