My dad and I are having an arguement about what to do with a stock 48 Willys.:mad3: Our main passion is Early Broncos, but we also have a 48 willys. It is something that we would like to make into a semi hardcore trail rig. I have heard a lot of opinions about the stock frame. My opinion is that if we are going to use the stock frame we need to box it in to strengthen the frame. Several people have told me that the frame is a week point because it is C channel and not fully boxed frame. My dad says that he has been looking on the almight internet and has the opinion that the stock fram was a cold rolled steel frame and was made to be able to flex, and should leave it as is. I don't think that people in 1948 had the same idea for the willys frame as we do (rock crawling and semi hardcore trail riding). What do you guys think? I don't know if this thing is going to end up with the 134 L head in it, small V6, or V8. I know that will have to come into play also. Probably will have full width Dana 44 and either Dana 60 or Ford 9". What opinions does the mighty PBB have?

Yes it was origionaly made to flex, but for a trail rig flexy frames = cracked frames. Do your self a favor and box it to start with instead of having to redo it after it cracks.

My dad and I are having an arguement about what to do with a stock 48 Willys.:mad3: Our main passion is Early Broncos, but we also have a 48 willys. It is something that we would like to make into a semi hardcore trail rig. I have heard a lot of opinions about the stock frame. My opinion is that if we are going to use the stock frame we need to box it in to strengthen the frame. Several people have told me that the frame is a week point because it is C channel and not fully boxed frame. My dad says that he has been looking on the almight internet and has the opinion that the stock fram was a cold rolled steel frame and was made to be able to flex, and should leave it as is. I don't think that people in 1948 had the same idea for the willys frame as we do (rock crawling and semi hardcore trail riding). What do you guys think? I don't know if this thing is going to end up with the 134 L head in it, small V6, or V8. I know that will have to come into play also. Probably will have full width Dana 44 and either Dana 60 or Ford 9". What opinions does the mighty PBB have?

This is pretty simple. The C channel is barely up to the task at hand much less upgraded tires and engines. You need to box the frame otherwise you will be doing it later.

Box it.

Box it, but I would just build a new one.

I would just build a new one.

x2


less work! 2x3x1/8" or 2x4x1/8"

I agree to build a new frame from scratch would be best but we are building on a budget and this is our learn as you go project, never done anything like this before. Also our newly aquired welding skills have yet to be proven.:grinpimp: What is the best size metal to box with 1/4 inch? would you box the entire frame?

whatever the thickness of the original frame is fine to use for the inside. I'm guessing 1/8" maybe 3/16" but 1/4 is huge overkill!

this is our learn as you go project

Well take it from me who has had one of those learn as you go projects - toss the frame and build a new one from scratch out of 2x3 or 2x4 tube. I boxed my 42 willys frame completly with 1/4" as well as strapping it top and bottom and it was more hassle than it was worth when compared to just building a new frame.

I say box it. Those frames are notorious for cracking. Plus it's a great project for learning fab. Yes, it's a good size job, but if you're just learning, its an easy job. Fabbing a frame could get overwhelming.
And definitely use similar thickness material. 1/4" is overkill, heavy, and will just transfer weak spots to the old material.
Yes, frame flex helped for traction back then, but now we know better. Let your suspension do the work. Besides, that frame has been flexing for 60 years. It could use a little strengthening by now.

I say skip boxing it and build your own. When you consider all the effort of cutting the metal, fitting and then welding you could easily buy $200 worth of 2x4 and build your own frame from scratch. As having restored a 49 Willys and building a 42 Willys I can tell you, for anything other than street use and mild trail running, the stock frames suck. When you put on larger more agressive tires, better axles, lockers, and a more powerful motor you are going to crack the frame, even if you box it. I wouldn't waste my time to be honest, remember it is 60 year old C-channel. Fabbing a frame shouldn't be that hard if you have the original there to copy. But that's just my opinion.

Box it, and tie the cage to the frame in as many places as possible.

build a new frame, in the long run it will be more economical and be much stonger platform to build from.

build a new frame, in the long run it will be more economical and be much stonger platform to build from.

X2.

My boxed GPW frame is now bent after a few runs on Fordyce. Don't waste your time boxing a piece of crap frame. Buy some 2x4 .125 wall rectangle tubing, you will save time in the end by doing this.

Yes! For sure! Build a new one! The only reason to use the stock frame is if you doing a "correct" restoration. I spent more time welding/boxing/plating up cracks on my old stock frame than I did wheeling. But of course You should also read the rules and Keep this kind of basic newbie stuff out of the hardcore section. But then why shouldn't a 65 year old piece of junk steel made for a light, 40hp rig on little skinny hard tires hold up to a V8 and heavy ass axles on 35's. It really is a dumb question, from anyone that pretends to be hardcore. Hell them axles must be just fine behind a 350 too. Yes I'm a asshole, so what?

Build your own:grinpimp:

Takes less time than strapping & boxing, and its stronger. No need to go overkills, stock frames aren't all that thick to begin with. Mine is 2x3x0.120". Although I'll have a full cage from grill to rear bumper, and springs mounted to the cage, not frame.....

That pic scared me. Looks just like my garage except mine is a 3A. Nice looking 3B. Do you have a build thread?

box it, but i would just build a new one.x3

I just boxed my 72 CJ from the motor back, and it wasn't hard at all with a plasma.

If you have a plasma, I would say box it.

No plasma, just build a new frame. I wouldn't even want to try boxing a frame without a plasma.....maybe I'm just lazy

I used 3/16" plate for all my boxing if it makes any difference.

Yes! For sure! Build a new one! The only reason to use the stock frame is if you doing a "correct" restoration. I spent more time welding/boxing/plating up cracks on my old stock frame than I did wheeling. But of course You should also read the rules and Keep this kind of basic newbie stuff out of the hardcore section. But then why shouldn't a 65 year old piece of junk steel made for a light, 40hp rig on little skinny hard tires hold up to a V8 and heavy ass axles on 35's. It really is a dumb question, from anyone that pretends to be hardcore. Hell them axles must be just fine behind a 350 too. Yes I'm a asshole, so what?

Wow thanks for the advise. It sounds like you are extremely knowledgeable. Do you think I can just keep the stock axles and run 40" IROCs with welded diffs front and back. I am glad you chimed in I would have wasted so much money trying to build this thing right.:flipoff2:

Build new frame,I am using 2x3x1/8.40" Irocs on your stock axles that's a big NO!

That pic scared me. Looks just like my garage except mine is a 3A. Nice looking 3B. Do you have a build thread?

Not yet on PBB, on another site, though, yes. Its relatively mild by this boards standards: 4.3TBI/SM465/D300, Toyota axles, 37" iroks, 4 link rear, 3 link front with 2" air shocks.

I might put up a build thread over the holidays when I get the suspension hooked up. Here's where I'm at, on another board:

http://www.greatlakes4x4.com/showthread.php?t=112505