Project: Tetanus Shot - 1948 Willys

Got a little bit more done on the axles today. I popped the diff cover on the rear axle and about a gallon of water came out with the gear oil:rolleyes:. However the inside of the diff looked pretty good. I pulled both axle shafts and the 30spline shafts look very good. After talking it over with @MarsFab, I am most likely going to be running 4.56 Gears with a Eaton E-Locker in the rear and a Spartan up front. I am also going to convert the rear drums over to discs using Eldorado calipers and Chevy rotors.



I broke out the flap wheel and some wire cups and cleaned up the rear housing. Got it primered as well. Anybody have a good recommendation on paint that can hold up on the axles?



After that, I began working on the front. Now I have never worked on a front axle with hubs. I was able to get the caliper off pretty easily but was stuck with getting the rotor off. Big thanks to @rockcity for the helpful advice:beer:. I was able to pull one entire hub/rotor off the drivers front. The bearings looked surprisingly well for its age. Everything was greased nicely and rotated smoothly. I am planning on installing either Warn or milemarker selectable hubs. I am planning on stripping the front, replacing balljoints, and replacing rotors/calipers etc.



More to come tomorrow...:driver:
 
This rustoleum paint that you brush on is pretty tuff and keeps a slick surface so dirt and mud come off with high pressure water. Plus it goes on thick so it won't scratch off like spray paint.

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fordwheelinman said:
Did you completely scrap the leaf springs or are they still hanging around in your way?

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Do you mean the stock Wagoneer leaf springs? Yes I still have them. They are in pretty rough shape but could be salvageable. I do have all 4. I will be using the ubolt plates.

rockcity said:
This thing would look bad ass 4-linked with some coilovers or ORIs. ;)
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And a LS1 etc etc right?:flipoff2:

NickMaul said:
This rustoleum paint that you brush on is pretty tuff and keeps a slick surface so dirt and mud come off with high pressure water. Plus it goes on thick so it won't scratch off like spray paint.

c90334bb817d112e7797a51e8e46ed60.png



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Lowes doesn't carry it in the can just in spray paint. Guess I'll order it. Thanks!
 
I have a body:bounce:



Its a 1948 Willys with a title. Body/Frame are in good shape for the age with minimal rust spots. It's already setup for the 4.3 and has outboarded spring mounts. The frame has been stretched as well. The big plans for the body will be to rework the cage and stretch the body to match the frame.

Had to hook it to a tree and drag it off the trailer. Here it is in its new home.









The axles/cage work will be farmed out to @MarsFab in the coming months. I am planning on getting the front axle cleaned/painted and ready to go this week.
 
I've seen some cages built without bending tube that look OK and are strong. That is not one of them. That thing is just waiting to fold up on some unlucky persons head.
 
strange1 said:
I've seen some cages built without bending tube that look OK and are strong. That is not one of them. That thing is just waiting to fold up on some unlucky persons head.
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While it might not look the greatest, that thing was beaten hard for a number of years with no issues.

While looks aren't the greatest, a proper miter joint is as strong as a bent tube.
 
The cage is stout, no doubt. I am wanting to get a little more room in the back seat and can't really do it the way it is configured now. Tonight I ordered new rotors, calipers, and pads for the front end and I picked up a set of Moog U-Joints for the front end. I drained the oil, pulled the spindles off and got the shafts out.





The bearings look great and will be reused. I'll repack with grease and reinstall them. While I am doing the front end, I will upgrade to a selectable hub system.

I got 1 Ujoint apart and had to call it quits so I could cook dinner.



Tomorrow will be spent working on getting both new U joints installed. Rotors/Calipers will be Wednesday.

Zack
 
I don't think anyone was busting my balls:confused:. The cage will be removed and replaced with something that will allow a bigger backseat. The cage is stout as hell and I have no doubt that it served its purpose well, it just won't serve MY purpose. Everything else on the Willys looks solid and well-built.

Got the new MOOG U-Joints installed in the front axle. Not to bad a job.



I'm going to pick up rotors/calipers/hubs tomorrow and get the front buttoned back up. Then it will be cleaned/primed and ready to go to @MarsFab for gears/lockers. I ordered the rear disc brake conversion and need to get the calipers as well. Anybody got a set of Eldorado calipers laying around?

Suspension wise, in a few weeks I will have Wrangler rear springs in the front and Dakota's in the rears. Now the previous owner had it setup for SOA. I am going to stay SUA and was wondering if the stock wranglers up front would push the nose down. Should I go with a 2" leaf spring or would stocks do well?
 
So very little of the original crusty critter is being used! Got any plans for the tetanus metal?
 
Sadly you are correct :(. The original is in very bad shape. However, I am going to try and use the dash and the tailgate. I'm going to try and use the hood as well. As with most projects, this thing keeps evolving as the build progresses, which can be a good thing.
 
What are you plans for stretching the body? What wb are you setting it up for? Extending in the door, behind the door, 4 dr?

have anymore "bodies" with titles? Ive got 1 flat fender but wouldnt mind have another "start" to one.
 
paradisePWoffrd said:
What are you plans for stretching the body? What wb are you setting it up for? Extending in the door, behind the door, 4 dr?

have anymore "bodies" with titles? Ive got 1 flat fender but wouldnt mind have another "start" to one.
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Looking at how the body is cut now, it looks like I would be able to cut in the middle of the rear wheelwell and just push it back. The seats have already been moved back and into the rear wheel wells. I'm not too tall of a guy and I'll be moving them up slightly so its comfortable to drive. I don't have a number yet on the WB. I am supposed to be picking up some leaf springs from a couple members here and once I get them I will hang the axles and measure WB. It will definitely be longer than stock. It should be close to the same as what the PO had.

I don't have any other bodies/titles. I do however have two frames. One is in excellent condition with the original shock mounts/shackle mounts ground off(this was going to be my frame for the build). I also have the 1951 frame that has all the mounts but in slightly worse shape.
 
I really want a flatty now. If I get one, it looks as if it will turn into one of those addictions where I will end up with 2 or 3...

Good work man! Keep it up. I cant wait to see this thing "finished" (as if any build ever is).
 
DannyH said:
I really want a flatty now. If I get one, it looks as if it will turn into one of those addictions where I will end up with 2 or 3...

Good work man! Keep it up. I cant wait to see this thing "finished" (as if any build ever is).
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I do have two frames for sale....
 
Parts keep coming in. I need to get the gears/lockers ordered so I can button up the axles. Picked up the rotors, calipers, and MM selectable hubs today. The Advance guys know me by name now...



Need to get a couple more flap discs and then I'll start on the front axle.
 
Got the front D44 all cleaned up this evening. Ordered the rustoleum hammered paint in the quart, should be here next week.



Ill be ordering gears/lockers from ECGS tomorrow and then its off to @MarsFab next week. Going with 4.56 and Spartan lockers front/rear. Originally I wanted to do a selectable in the rear, however with the added cost of cage/body work I feel like that money can be spent elsewhere. This won't be a daily driver by any means so it should work out great.

Got the Wiring Harness from Jim's Performance back today. This thing is clean! Everything is labeled clearly and the wiring harness looks a lot better than what I sent him. I'm going to go look at a set of 36" Irocs and some Eldorado calipers tomorrow. Once the axles are at Marsfab, Ill begin installing the drivetrain and getting the interior setup for gauges etc.
 
Well its been a busy weekend. Meet up with @R Q and grabbed a set of 36" Iroks. I also picked up a set of Eldorado calipers from him as well. Got a nice package in from ECGS as well. Still waiting on the Spartans, should be here this coming week.



Saturday was spent doing honey-do items around the house. So today was devoted to the Willys.

I got the motor primed with oil and installed.





Started mounting up the accessories/headers. Got the drivers side header installed but had to run a tap through some of them. Apparently they make good dirt dauber homes...




And heres a problem on the passenger side. The flange on the header hits the side of the frame.



Its hard to see but I think that if I were to cut the flange off, it would clear. Anybody got a better idea?
 
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It's hard to see how much it's hitting with the pic. Maybe use block huggers? Or cut the header and add in a small bend to get the flange off the frame
 
Stayed home today because we got some furniture delivered. Got a lot done. On to the pics...

I was able to clear both headers by sliding the engine over to the drivers side by about 1/2". Luckily, the motor mounts had extra holes in the mounts so it was as simple as unbolting the motor and sliding it over.



After I got the motor positioned correctly, I was able to mount up both sets of headers. After the headers were installed, I got to cleaning the TBI and installed it. I also stopped by Lowes and picked up some mics bolts and got the water pump installed.



After the water pump was installed, I moved to the top of the motor and began positioning the power steering pump and misc hoses/electronics etc.



I still need to pick up an alternator for it as well. I also have room for an AC compressor. AC in a Jeep this old is kind of worthless so I think I am going to try an OBA setup with it. I still need to source the compressor and the parts but I do have the option.



I still need to torque the crankshaft pulley bolts but will wait till the transmission is installed.

I also got a couple more packages in today.





Axles are ready to go to @MarsFab in the upcoming weeks(as soon as he makes room!). I'm supposed to be picking up a set of Dakota leafs for the rear this weekend.

My growing parts list keeps growing.



All of the components for front/rear discs. Still waiting on the disc bracket kit from TSM but it should be here by Friday.

Starting to really gain some traction now.
 
Got some more done today. Rolled the tires next to it. Really digging the look :bounce2:



Pulled the seats out of it and cleaned up the interior.



Removed all the excess wiring.



I think I am going to try and splice the gauge cluster from my dash into this one. It shouldn't be too difficult. The dashs in these old Willys are welded in so I'll just cut around the gauge clusters to make it nice.

The dog has decided he already wants to go for a ride...



Pulled the cage off. That was fun. All of the connections were bolted but because of the way it was assembed I ended up just cutting off everything with a grinder.



Removed the fuel tank/cage around it as well.



So, after removing the cage I am planning on stretching the body. I should be able to get about 9-10" more in the body. I'll accomplish this buy cutting the fenders. As you can see in this picture it should be fairly straight forward. I'll patch everything back in with 16ga metal. It will be my first time doing any kind of sheet metal work....should be fun.



This will give me more interior room and ability to have a rear seat/storage space. I still need to clean up a lot of welds with the grinder etc. But it is starting to come together.:driver:
 
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