I have started and test driven the car enjoy the PICTURES!!!
Starting, Away and back !!!
There is more to mount such as bumpers and some of the interior.
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Driving
Author Archives: Ragnar Adell
Frame ready
The most of the frame is ready with mounting the fuel line from the gas tank which also is mounted. The body is ready from the paint shop. The mounting of the front window with the rubber around .The tube for the ignition cables was made and mounted. The many small items that has been to the chrome shop has arrived.
I have worked both day and evening trying to get ready to 8th August to register and get number plates for my older sons wedding the 27 August!!!!!
The last days I have mounted the most of the wiring and connected it all according to the electrical scheme. The radiator and the shell is also mounted in place
I have also got the inner roof done .Mounted the dashboard and some of the instruments. The engine has been running for total about 30 minutes and so it happens -the rear frost plug went out and all the water went out!!!! Much work!!!
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Engine work
The engine work is proceeding with mounting the muffler and the exhaust pipe with the stay that holds it in place. The distributor, condenser, cables, lock, breakers all adjusted and ready. The carburetor and the fuel pump is also in place and also the starter and generator. The small front rubber is cleaned and new rubber made. In all means READY to start for the first time.
It all went great some adjustments is to be taken care of for the carburetor and the starting motor. The battery seemed to small even that I used an 6V 84 Ah
The propeller shaft was a new made and it has been adjusted and welded in a shop.
The fenders is painted and ready to be mounted so is also the side plates between the body and the step plate.
The body has been delivered to the paint shop!!
The rear and front bumper is delivered to the chrome shop where I also collected the radiator shell and some others parts.
The fuel tank is mounted.
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Body paint
Just now the project is going with high speed.
The body has been removed from the frame. The body is put on a wagon that is drawn to the paint shop. The frame is painted black. Some of wood interior has been removed.
The brake cables is tested and the wire has been pressed in the ends. The front cables is mounted in place.The front brakes is ready.
The wood graining is finished and the parts is ready to get a layer of varnish to get a god surface before I mount it in the car.
The rear wheels is new tubes mounted so I could use the old tires when working on the frame.
The engine is mounted in the frame so is also the clutch and the gearbox. I have made new rubber mountings.
The steering is mounted to the front axel.
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Instrument panel
Just now there is much of the work that has been done, started and finishing at the same time!!!
That is the hole instrument panel was delivered to me from WOKR member Sven Olof Johansson in Sweden .He called me on the phone and said that he had one panel with bezel and the temperature instrument with amp and oil with parts to the fuel. I had to make some parts to the fuel gauge and repair the copper line. The panel with the figures is a new scale being made. The gauges for speed and temperature are handed over to a shop that makes a new speed cable and sensor to the temp gauge ..
The panel and the inside window panels is delivered to the paint shop. The wood graining will start direct after that he had laid a layer of base paint. The pieces that going to be painted black is delivered to the paint shop.
The cylinder head was soldered with high temperature metal powder that melts in the crack. The head is then straightened and painted.
The brake cables is being done and new cables is made from an SAAB handbrake with little modifications. It means making rivets, cutting cable and making new ends.
When measuring the foot step rubber I got an idea of making a pattern from the wheel hub and make a bigger pattern in the rubber mat.
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Many different jobs
This month I have not worked so much because I have got the flu. Nothing was done for 14 days.
At the right front fender rear end I discovered a buckle which I was forced to drill and weld to be correct.
The carburetor was sent to the shop that would help me to clean and adjust it with the service kit I had bought.
The clutch was sent to a shop and arrived a week later in shape as new. I also made the anti rattle springs for the clutch release levers after the drawing from Greg and WOKR.
The cylinder head in the shop got a visit from me to se if he have made any progress but he should do it in this week …..
I turned and drilled the holes for the thick washer to the exhaust pipe that fits on the exhaust manifold.
The aluminum trimmings has been adjusted and mounted on the foot step to see how would look like.
The water pump is next to be mounted.
I hope to deliver some parts to be painted in the next month, perhaps………
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Fenders and fotstep
The last month I have been working with the fenders and the footsteps with trimmings. It is the aluminum trim that I have pressed new several times and at last got the right look.
When working with fitting I saw that the fenders connection to the footstep and the trim did not matched quite good Much time spent on remaking the plate and the pressed edge from the fenders to match with trimmings. The work that remains is to make holes in the footsteps for the trimmings that I shall fastened from the underside and make threads in the trimmings.
I have been to a shop for chroming and delivered the in- and out-side handles, parking lights, wings screws for the trunk rack and the bumpers center clamps. The glass the original ones is also being fitted here I would make new ones for the turning lights.
I have got an gasket kit for the carburetor. The carburetor have I dismantled and tried to clean with acetone. The gaskets for the manifold and intake has been delivered to me also.
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This year began with
This year began with the job that I have worked with in December that means much time is spend doing the surface ready for painting. Which is to look after small dents and other small mistakes working with light from the side to the surface. That means the rear plates and the right side has been apart and welded some bolt holes and correcting the mounting so it all fit proper together .The hood shelves (plates under the hood) has been corrected so they will fit better now. The left rear door has been adjusted so it will work better when closing it.
The shock absorbers is ready. They have all been mounted and painted black. Next step there is to fit in to the frame and the axels with new rubber inserted in the link tubes.
The other big work this month has been to make the trimmings for the running boards. It began with taken the old ones-I had some fragments! Measuring it all angles and so on. I made a tool and after much trying. Several hours later it looked alright. I would buy a rectangular aluminum plate with 6mm height and about 20mm width this will be mounted on the upper side and fastened with pin bolts from the bottom.
I have not heard anything from the shop that would help me with the crack on the cylinder head.
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Handels and cylinder head
The most of the time this last month I sanded and polishing the indoor handles, riser handles and park light .In the riser handles I drilled a hole so they will fit inside the door .
The old door knobs where reconstructed with new pins and the end there where tapped to fit in the handle for a screw.
I have made new escutcheon for the outside handles.
The cylinder head is moved to a shop that could repair the small crack .He would fill the crack with powder and heat it up and let it cool slowly before he straighten it up in the mill.
The shock absorber that was so bad has got new pistons, springs, washers ,new lock bolt , new tapped filling hole with a bolt and a new big plug washer. The three others was only to refill with oil.
I whish all of you who is follow my job a Merry Christmas and a Happy New Year.
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Waiting
The project has gone in some what slow motion. I am waiting to get the paint on the car. Just now I do not know how is going to do the job.
The making of new handles inside- and riser handles, parking light and the small riser handles in the rear is going in a new phase. I have got them from the foundry and I am now sanding and polishing them for chroming.
The radiator shell and some other small things is ready and waiting for me to pick them up in the chrome shop .
I has finished the work with the dots or badges that holds the bumper in the middle. You can also see that I made new wing screws for the luggage holder they are ready for the chrome shop also.
The cylinder head has still a small crack between the water hole and the no.1 spark plug hole. That despite welding with special stick. I am thinking of what to do. I have some ideas that I have not tried yet. So still there is hope.
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Went on making
Went on making the bezels for the instrument panel. I started with making many test bending in copper because of it is much easier to chromate them later. After thinking and making a toll to press the bezel in the middle I got an idea of making it all in iron and then polish and hand them over to a shop for chroming. I decided to do so because I should only make one of each bezel. First I cut a 6x6mm long bar then I bended it with hammer so it would have the right inside measure .Then I made one fourth end ,the short end and welded it place. I finished with filing and sanding so the would fit in the panel. This was the procedure for all three. It all ended up with polish it all to be chromed. It is nearly the same measure like the original.
I also made the button from the steering wheel I turned it from an bakelite round piece .I thanks John Stokes for his concern sending me a photo of the steering wheel from there I could make somewhat similar button.
To the water temperature instrument I made a new scale look better out when mounting in the instrument.
The thermostat issue I tried to solve in an various of ways. I was talking to my brother he said:-“Try a VW thermostat”. I did so and it is somewhat smaller but is works. It looks like it moves in the same way and in the same length. I have got many figures and ideas from Lloyd Gauerke so I could compare his information with what I tested .I have not tried it in the car yet.
The shock absorbers is just now undertaken a big dismantling one is only to fill with new oil the others need more job. The fourth is rusted and stuck I needed to crack one piston.
The hood had shown some mysterious spots. It was rust! I decided to sand it to bare metal and after that some acid that get down to the small spots and removed the oxide.
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Summerjobs
Wondering what has happened with my project????
In this summer the Willys 8 project has been going in slow motion because of working in our house with repairing ,building and setting wallpaper in the kitchen followed up with rebuilding the bathroom and shower. That has taken the most of my time this last months.
But …..
There has been some progress in the Willys project :
I have made the installation of the roof top .Beginning with jute pad in the bottom which was nailed in place .Next step was to lay the synthetic padding and finish with top fabric . I have also fasted the aluminum rail to see how it all will fit it will be taken of before the painting.
The steering wheel was repaired and painted the job that remains is to make a button .I have also started making the chrome rings for the instrument panel
The radiator shell and some other things has been delivered to a shop that would help with chroming.
I have found a Carter BB 1D carburetor that need some work but I think it would fit.
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Radiatorshell
The work since last has been concentrated to the radiator shell. New plate in the bottom has been made and fitted in place. After that welded and grinded and welded again some times just now it looks good. It is still some work to be done before I hand over to chroming.
I have also made new garnish moldings to the rear window. For the lower molding was a tool made to get the right look regarding to the other windows. There is some work left before it would be finished.
The front axel was mounted to the frame and the bearings ,drums with new paint and wheels was mounted. The brake shoes was cleaned and ready for new linings to be glued in place.
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Engine work
The work from February is proceeding with mounting the oil pan which had become a layer of black enamelbefore mounting with new made gaskets. The floating oil intake was mounted. When mounted all that I turned the engine and made a bed of wood so that would be easier to mount the rest in upright position. I has also adjusted the valves to 0.010 ” clearance. The new timing chain as mounted and a new ignition mark was stamped on the flywheel. I made new washers for the freeze holes.
I have mounted and fitted the clutch assembly was forced to change the bolts into new with insex heads because the where made in the highest quality. The clutch plate should I send to someone can make new discs.
The man that is helping me with painting the car has inspected the work that has been done by me. He took a careful examination. He said it would be nice to paint it. I could dismount the fenders and the other plates.
Now it is only for me to choice colour !!!!!
The radiator shell ,headlamps and the front bumper is proceeding some what .The shell is dichromate and ready for repairing Which I should do later. The head lamps was undertaken a cleaning with some light acid .The results was astonishing .OR! The bumper is going to be sanded by me later.
The front axel is ready to be painted and mount the bearings after new bushings and king pins.
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Mounting the engine
The most of the work the last month has been regarding to the engine. The first item that I mounted was; the crankshaft and mounted the main bearings. It felt ok when I draw the crankshaft around a couple of times. At the 0,030 oversize pistons Imounted the piston rings . There where 2 of the oil rings. The lower one I was forced to file to make the right end play which I choose to 0,40mm .Which ended up with that I filed and fitted each piston in each cylinder. When measuring the fittings of the piston pins I also grinded the holes to correct alignment. Even the connecting rod bushings was some needed to be refitted. The piston and main bearings mounting ended with securing it withcotter pins and wire . The distributor was undertaken a complete dismantling and cleaning all parts.Painting anddistributorremounting the most of the parts left to be done is mount it on the engine the adjust and synchronize the breakers.
Flywheel and the clutch faces where machined.
The fan drive pulley was machined ,cleaned and ready to be installed on the engine.
I had a talk to the shop that is doing the chroming to the lamps, bumper and the radiator shell. He had not been doing any work -yet.
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Engine home
The year 2004 began with plastic filling the surface at rear doors. Then proceed with an layer of primer. The next step was too go further and do the same work at the rear fenders and the left front fender. That work was finished with a layer of primer.
The most exiting moment this month was when I went to the shop to collect the engine. The work that had been done is drilling the cylinders to 0.030 oversize pistons, new wrist pin bushings in the connecting rods, new valve guides for the valves that has been machined, new seats is machined to all valves both out and intake, one new cylinder sleeve to number seven cylinder and at last the hole block was machined to level . When examine the top I found out that the was an crack by the thermostat house and it was sent away to a shop to be welded and level it all to fit the engine.
After the engine come into the garage I cleaned all the threads. When that was finished I cleaned the hole engine and laid oil to all surfaces to protect it .All small items is cleaned and put in a pot of diesel
I has also began to measurer to the instrument panel and found out that was a possibility to use new instruments that would rebuild to fit in proper. BUT it would be nicer to have similar to the original.
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Chrome and minor jobs
This month I have been working with many small things and delivered front bumper, radiator shell, head lamps and front seat irons to chroming. I tried to repair the shell but it seems to hard for me to do that. I needed help and it looks like an experience hand would help me.
Adjusted the right rear door so it would be smooth and nice to close and fit proper in the body line. When doing that I also tries to make a good finish at the door sides and all the surfaces that would be painted later. Even the left door was some job on like in the right side.
The front bar between the front fenders has been changed because so the radiator shell would fit better.
I visited the shop that helps me with the drilling and changing of one cylinder he would perhaps finish it under January some time????
I mounted the rain drain holder under the rear windows. Drilled holes for the footstep and threaded the bolts in the frame. Adjusted the left side fenders so the outside line is ok.
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Radiator and steering
There is not so long ago that I wrote in the dairy but there is some small goals that has been achieved.
The first “big” surprise the last month has been when the radiator shell and the headlamps came from Greg that had delivered the package to Hershey swap meet where my helping hand picked it up and sent it to Sweden. When I fetched the package I also find an universal joint for the rear axel connection that Kjell in Örebro had in his barn.
After much trying and lot of muscle , warming and a lot of thinking at last the steering wheel could be loosen from the steering column. The outer pipe was very damaged and rusty which I changed to a new one.. The contact in the bottom of the steering column where cleaned and the long rod where also new and with the ingenious connection to the contact which I found much information on the WOKR website. The hole steering mechanism where at last painted black. The steering wheel is now being restored. I should also make a new button at the top that fits to the steering wheel.
The front floor ,the toe board and the plate under the front seat has been mounted. The picture shows also the iron that holds the front seat mechanism.
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Already November
It is already November when I am writing this.
Under October I began within making new outside handles. I made a tool to press the handle skin, but after making some (many) testing I decided to take the old ones and make only one new. That was after many ,many hours of testing.
Made new glass settingchannels for all windows. Fitted the front window with all mechanisms. That one is ready for paint, rubber and glass.
Delivered the front axel to Sören so he could help with the the spindles, bolts and bushings. The bearings has arrived.
Mounted the front springs with there shackles in the frame.
Thefloor in the rear under the seat has been mounted and welded in place and finally got an layer of paint over it.
The wooden floor in the rear and thetoe boards is just what I being working with now.When getting it fit proper I also fitted the steering column and the flywheel house with pedals to see how it would work with the toe board.In the same time I also working with thefront seat and the mechanisms that moves the seat .Sandblasting, painting fitting and threading the holes.
I shall say -Thank You to Mike Barbour who is helping me with measures for the front seat and the rear bumper. The last one is handed over to on helping hand who would bend and curve the irons.
The radiator shell and the head lamps is shipped from US to Sweden and would perhaps arrive November or December.
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Steering and universal joint
This month I have been working with the front axel in terms of ordering bearings and trying to machine thespindle bolts to dimensions that fits the bearings. When working with that I contacted Sören and he advised me to get it all done at the same time in his workshop when the bearings arrive . Meaning new bushings, spindle bolts, and a bigger hole in the axel. The axel and some other parts has been sandblasted and got an layer of primer.
The gas tank was finished soldering and fitting the gas gauge and painting it all black.
The rear universal joint was cleaned and examined .With the result of new must be mounted. Find one is not easy but I have contacted one that had the Mechanics data sheet for my universal joint.
Thegear box has been mounted in all parts and after I got some small parts from Kjell in Norway I succeed to get all work proper.
The shock absorbers has been examined an one was ok ,two is needed be serviced and one must completely restored. I have been making pin bolts and nuts to two of them.
The last thing I have done this month is making adjustments to the right rear door.
I have also been in contact with Greg Gumtow and he would help to get the radiator shell and headlights from US to Sweden.
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Information and dismounting
Hi everybody that is enjoying my job on this project. I hope that you not have been disappointed when visiting this site and seen that I have not written anything during July.
When Kjell visited me in May he took some photos of me and my car. He also took a trip to Sören and looked on hiscar.
There has been many mails to WOKR members trying to get information regarding the front axel. I have also got some help from everyone that answered. That ha give me a solution to the front axel adventure .I have disabled the axel into some parts that would got to be sandblasted and the parts that I have cleaned myself.
All the hydraulic shock eliminators has been cleaned and is ready for new oil and paint. The transmission mounted but there is one part missing. The flywheel house cover with axel machined and pedals with new made bushings. All has been cleaned and ready for paint.
The front window is dismounted in all it parts remounted ready for paint and glass. The petrol tank is in progress with a helping hand from a workshop and then I made the sides and mounted the tank filler neck .The gas gauge is not yet installed. The rear trunk luggage rack is fitted in place When working with the rack I discovered that the rear bumper is missing anyone that have measures
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The spring cushion and frontaxel
The spring cushion is going to be fitted in place and I have to talk the person who is going to help me I have also been repairing the rear axel for the Whippet 96 it was leaking oil into the brakes which I was forced to repair.
The front axel chapter is in some progress I have some doubt about the strength which one to choose but it seems just now that I will choose the axel from the Willys 97.The drum looks very good and I am forced to drill for the wheel bolts so that they will fit my wheels. Some e-mail has been sent to members in the WOKR that perhaps has some answers.
The plate that covers the gas tank has a new one been made. First to make a tool that make ribs and then an other tool that make the round hole. When they have been stamped I made the plate to fit the curve on the frame and last to fit proper in place
A new bushing for the main shaft in the gear box has Sören made to me. He also has fitted the new ring gear to the flywheel.
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Visitor and fitting the body
This months highlight was when Kjell Fagerland visited me. He had two hubcap to my car! Thank You Kjell.
The most of the time I has spent within making the body to fit proper to the fenders and the footstep. I am not ready with that yet. That means welding ,loosen bolts,drill new holes , fasten 1/4″ UNC bolt with washer and nut and outside finishing with plastic filler and at the last a layer of primer. It takes a lot of time. The work left is the rear fenders where it is welding to be done in the front lower end to the footstep in both sides.
The radiator shell is still laying waiting to be sent to me the only problem is to solve the transport to a reasonable price.
I am measuring to see which way I would fit the frontaxel.
The left rear fender
The left rear fender is more welding done and I hope also the last of welding on that fender. The bolts has been set in the correct place and the fitting is now correct to the body.
Mounted the brakes on the rear axel. There is only to fit the brake cables and calibrate the brakes.
Greg had sent me a mail and said that he has one radiator shell that needs some repair work. I told him that was ok for me and that I was interested of buying it.There is only to find a cheap way of sending it to me.
The radiator is ready and I have mounted it in place to see how it fits..
The rest of the time I have been adjusting the door and roof on the right side ,welding,sanding and plastic filling so it is nearly ready for painting!!
I am waiting for the engine.
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Bearings and rear axle
Since last month I have had an cold and was out of work enthusiasms some days. But never the less I have been working with the car. The springs in the rear is mounted with grease between the leafs.
The rear axel is ready.
After some trouble with the outer bearings and that I have tried to improve the tighten .The rear cover had become a new cork sealing. The differential bearings is secured with steel wire-like before. There is new grease nipples. The brakes is not yet mounted and brakes linings is new and has been glued to the brake shoes. Thank you John for the photos !!!
The springs and the rear axel is mounted to the frame and the shackles is mounted with new bushings reamed both in the springs and the frame. The rear axel is filled with oil. When I tried to mount the U-bolts they where 30 mm to short. That was only to remount the tools for the press and making new threads to the bolts there went 4 hours!
When I fitted the rear fender the sill was not fitted correct I had to make a new one .
Total amount of time 1015 hours
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