Category Archives: Engine

Interior and carburetor

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Even if the most of the big restoration work is done there is still much to improve.
I have mounted a roof lamp which is controlled from the dash.
The ignition coil had to bee changed because it was burned. A new one was bought.
The trunk in the rear is in place and there is still some clothing and a couple of boxes in the bottom that I shall make for tools and service.
The carburetor problem is still much thinking about.I have got a Carter BB1 with accelerator pump there is some of the internal service to be done some of it is stuck!
The water temperature gauge is not showing correct temperature so I have made an experiment with one IC circuit that helps to show the correct temperature. Next step is to dismount the temperature sensor and make a test bench for that and the gauge and see what that gives me.
I am thinking of making two spare tire covers in steel….
Beside all that I have driven the car around and …..just enjoying it.

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The most of the time

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The most of the time since July has been driving around with friends and weddings.
During these trips I have trouble with the fuel.
When investigating that I found out that the gas tank was much dirt in most rust I thought.
I empty the tank and dismounted, cleaned with heat water and high pressure after that I
Poured in acid and washed with water. After drying it was time to pour in a can of Hirsch Tank Sealer
A couple of times and let that dry for three days. Mounting it all in place with a small filter in the bottom also. I have also welded a bottom screw for empty the tank in the future.
Then I tried to start I was forced to pump the gas pump by hand when mounting it all in place again I succeed to crack one ear that holds the pump. After some days I managed to by a NOS part.
I also switch the cork in the glass bowl after that I discovered that was also leaking air.
Now is the car running again? When driving around it I got a scrambling which disappeared when depressing the clutch. I dismounted the gearbox and the clutch and discovered that the nuts had loosen it was only to draw them tight again and mount all back in place.
The good news is that Ray Pfiorini sold two of his hubcaps for Willys8 to me .Thank You Ray.
The other big news is that I have sold my Whippet 1928.

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fuelhub

fuelarm

Frame ready

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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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front

innerroof

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dash

chromeparts

Engine work

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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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Instrument panel

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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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top

Many different jobs

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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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exhaust

Handels and cylinder head

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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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sirutabak

Engine work

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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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lamp

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Mounting the engine

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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

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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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I have just visited

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I have just visited and took a look at the engine, valves, pistons and the bushings for the pistons.
Then I went to get the rear mainleafs that got eyes for the shackles and the bolts.Then I needed help to bend the rest of the leafs. to fit in.
The bearings for the rear axel and the pinion had also arrived.
The rear fender on the right side is made new plates and and deal of welding and fitting. Some work just now to fit the rear end of the fenderotherwise finished with that.
I have also dismounted the radiator and got to a shop that would help me to rebuild it.
Just now looks the right side like this.

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The work

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The work for this month has been somewhat plottery.
The parts that I had become help with was not ready and I was spent much time to talk and ask for them to make some progress but……The parts is the head leaf to the rear springs I was getting help to make the eyes for the spring bolts but they was somewhat busy just now…The bearings was one week only a day or two away but I have not seen them yet!
The engine has been milled I he said that it was time for me to come and see if the eight cylinder is being to rusty or he was thinking of to make a new cylinder.
The radiator shell is till missing-someone that have one left? I had to think if I shall make a new one .I have being thinking and trying with paper and see if it is possible for me to make one.
But some real work has been done .The footsteps are made in 2mm steel and fitted in place. That took much time to fit the footstep to the front fender and the side plates. I had to remake the rear of the front fender so that would fit to the footstep. After that I was eager to see how the rear fender would fit to it but… I saw had to be a great deal of welding and fit some new plates in to the fender so that it shall fit proper. I began to take away the sill plate in the rear door and remake and fit the plate below the rear door.
The job with the front fender, the wheel trunk , the iron that holds the spare wheel ,side plate and the footstep was finished by painting with rust primer
PICTURES SEE NEXT MONTH!!

Under the first weeks

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Under the first weeks in June I have made a lot of work. The rear axel from an 1937 International Truck is dismounted and found being nearly the same measures the ratio is 11 to 46 which is some less in against 10 to 44.
Now I would dismount the rear axel of the Willys and see if there is the same measures and then I can mount the things together in one rear axel.
The floorboards in plywood has got an layer of Ash-tree and then being measured in the right size. The edges is being glued. Then it had been painted black in the outside and inside it is being varnished.
The plate floor I had painted black on the outside.
The gearbox is totally dismounted and bearings and the main bushing is new .The gearshift end is yet missing.
New pistons, pistons pins and rings are bought and waiting on to be mounted when the engine is machined.
The rear seat and back had got new wooden frames and ready to be mounted with the cushions which I going to be made!!!

This month I have cut

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This month I have cut the the leafs to the rear springs. The leaf package I left to a person that can help me to get the right curve and the eyes for the spring bolts on the main leaf.
The front fenders mountings in the spare wheels trunk where new plates made and even machined the rivets.
I have a helping hand to make a new gasoline tank.
A visit to Värnamo by Mats was ending with that I got the headlight bar with some rusty headlight and a couple of restorable rear fenders.
The rear axel is in progress. The pinion and Crown wheel was getting ahead by Greg at WOKR. He sent me some drawings for that purpose. John Stokes wrote from New Zeeland an e-mail. He wrote that International Trucks from 1936-41 has the same or interchangeable parts for the Willys8. Even the Borg-Wagner with no. WX2068-2069 was also a possibility.
The radiator shell was also taking a step forwards by some drawings and an ads in WOKR Newsletter .Which I am hopeful looking forward to get some answers from members.
The Engine restoration was in some progress also .I made new nuts in right size and hardened them also. All together 29 pieces I made two more then required

I have mounted the roof

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I have mounted, screwed and glued the roof ribs in place.
The side rib that is fitted along the body over the doors I have reparied and make new 50 cm long end on the left side.
Just now is tha car like thisSee picture.
The front window is taken a part and ready for sandblasting. I need to make or find a new handle that fits to the window also!
New wood from ash is byed and just now it is in a warm place to dry well a couple of weeks. Then I would make seats and backs for the cushions and some of it would also be floor in the rear. The wood piece is 65 cm width.
I have made a tool to make a wheel trunk in the right front fender. The right fender is welded,repaired and the left side is not all rust holes reparied.See picture.
The fotstep pins is reparied and welded on the right side. The left side I had to remake one from a wrong one that has been there before.See picture.
Greg in WOKR has done lots of work with helping me to get the right measurs on almost everything that can be measured, thank you Greg.
The engine project is in progress also. New main bearings, connecting rod bearings are made and the crankshaft is machined. The hole engine is now mowed 300 km nearer me and a guy should help be to bore the engine for oversize pistons and fit the valves.
Here can You see how I do to get an Willys 8(engine) in the rear of my Volvo 850.See picture.
I have found a new start gear to the flywheel and it was posted before Eastern than I would get some help to fit it in place.See picture.
The pinion project is in progress. I would visit a junk yard that have an Willys six 1931 chassi and see if the rear axel details fits.See picture.

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This month roof work

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This month I have proceed with the aluminium roof cover and sanded,polished them and they look like new again!See picture.
The door sill plates in all four door is made,fitted and primed.Also the upper plates are made after the old ones.See picture.
The roof is varnished and placed in but not mounted. See picture.
All the woodscrews in the bottom wood in the rear and some others that remains are mounted
I have met a contact in Boxholm how has an Willys model 97 1931. I am interested in to take some spare parts from it.There was none pinion in the rearaxel!
The startgear on the flywheel is in progress I have found a spare parts that is correct and NOS.See picture. I also ordered a timingchain.
I have taken some picture of the rebuilded starter!picture.

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starter

flywheel

Cleaned the valves

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Cleaned the valves so that I could measure them for buying knew ones. Checked with people that could have some and asked for prices. The same work was with the pistons.
Asked for incurrence papers to fill in from MHS.
The man that had electrical parts phoned and I bought distributor, ignition and condensator .
Visited the firm that would undertake the milling and factory work with the engine and we decided. That I shold come back when I had fixed the exta big hole in the block so that it was correct.
The engine was stripped and cleaned all the bolts and things without two pins and the camshafts bushing and shipped out to the man that fix the hole. The plates outside the vents was cleaned ready for sandblasting so it is with oil pan tray also. The cylinder head is ready for to be cleaned also.
All the wood parts was taken away and I took it for sandblasting when it was done and I primed all the body, fenders (all three!) and roof sides the doors would be done later when I have mounted in the right places. See photo.
All the things were carried away so that I could begin to fix the body in place for welding in the rear and in the front.

Took the rearaxel apart

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Took the rearaxel apart and the speval bevel gear was missing! Know I have an pinion but no rearaxel that it fits to.It is only to fix another rearaxel!
Loosen all cylinder head bolts one is broken and I have some trouble take it away and the same thing with the manifolds bolts three of them is stuck. See picture, nr 1 or nr 2.
Fitted the woodframe to the body and fitted it all together and the floorplates in the rear and in the middle was in place so that I was needed to cut and repass the woodframe.
Cut of the rearbody from the torpedo so the hole car is in three parts.
Beginning to loosen all the woodparts from the body and cutting all the bolts away.

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engine2

Engine and splash aprons

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Took contact with Mr. Mickos in Stockholm and he had some cushions for an Willys.
Made a tool that i could press the splash and after many trials I got and god result the remaining jobs is to press it in 90 degrees with an tall radius of¾”, I guess.
Enginework is proceding that two more pistons seams beginning to loos.
Got some intresting tip from Lorentsson in Lund that it is chance to get spareparts.
The woodframe is ready to cut from wood 1”x8” and glue it to better size and after a week I have beginning to make it fit together with the rearbody and the doors and torpedo.

I have sandblasted

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I have sandblasted the frame and painted with primer.
Posted mails to lost of people in Sweden and Danmark and Norway and did´t recieve any answers from anyone yet.
Began to losen and dismounting the engine. Four pistons of eight is probebly stuck.
I have visited Mats in Värnamo and got much good advice and good look at his Willys six 2-door 1931. Perhaps does he have an frontaxel for my model some small things also but no radiatorshell.
Mounted all the things so complete that is possibly.