Willys Wagon Build Idea ?

[ToyotaJeep]

Hello,

I am pretty close to deciding if my shop students and myself are going to build another Willys Wagon. We have built one in the past. I tend to need high-learning, high-labor, low-cost type of projects. They are mine, and I am not rich

Here is my intended use:

Occasional DD, lighter duty towing-a small car trailer once in awhile. Semi-comfortable ride quality. I mainly 4x4 in the snow, with some rocks and mud. I do see myself taking a longer trip or two in it with some wheeling. It needs to be able to fit between 35-40" tires, and be completely street legal. Parts available at any Napa store. Nothing fancy, just solid, strong and able to be used at any time.

Running Gear:

Ford 300-6, 4-speed, 205. Centered rear 44, and a D drop 44 front. Axles are out of an 86 and up Wagoneer. Leaf springs all around and it will be SPOA. Axles will be locked.

Here are my questions:

Frame-I am thinking of reusing the stock frame and redoing the front only. I have swapped a Wagoneer frame before which worked ok. I will not swap any other frame under there. Just can't do it due to appearance etc.

Stock frame and fix? Or swap / build a frame?

Gear ratio:

I will likely never go under 35's, but I won't likely go over 40"s either. Probably will run 38" radials in the snow.

I am thinking about 4.27 gears. I know 4.56's are the obvious ones, but I ran into too much gear with my other Jeep. It is actually better with 36's and 4.10's than it was with 33's. Plus the 300 is pretty torquey.

Recommendations on gear ratio? I would like to maintain some semblance of fuel mileage.

I am just gathering input right now. If we go this route, it will likely be later in the fall when we start.

And yes, I have been reading Midnightburn's awesome build.

Thank you.

ROB

[urjb]

I vote 4.56 and a fabricated frame

I ran a CJ with a six and 4.56's on 35's and loved it. with the 38's fuel economy should be OK.. 40's I think is pushing it, especially when towing. I had a F100 with the 300 and 31's, 3.50ish gears, and the mileage was awsome, but wasn't real fast, couldn't imagine towing with it.

Fabbed frame you can put all the pieces where you want 'em without the work of modding (cleanly) the stock frame from a Willys or Waggy.

[ToyotaJeep]

It will be running 35-36's most of the year. The bigger tires are only for use in the mid-winter when I wouldn't likely be towing anyways.

I thought the difference in frame width was quite a bit more, but by the time I widen out the front to match the axle, it would not be too far off to go straight all the way back. I checked it briefly yesterday.

I actually have four of them, and I am going to take the worst one and cut it up so I have a full size model near by to work off of for measurements etc.

Regarding the gear ratio, I may end up with the 4.56's. I know 4.10's will be too tall.

More to think on. I need a project, and everything else I need is going to cost too much right now without me selling another rig, which isn't happening right now.

Thank you for the input.

BTW-You liked the 300 it sounds like. Good to know.

ROB