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Old 11-22-2018, 07:44 AM   #1 (permalink)
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63 Willy’s wagon build

Got this wagon 5 years ago and got started on the build but then found out I was going to be a father and decided to rebuild the flat fender since it was going to be the easier rebuild. Fast forward 5 years, flat fender is done and now it’s time to get going on the wagon.


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Old 11-22-2018, 07:49 AM   #2 (permalink)
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63 Willy’s wagon build

Here’s what I started with...1963 Willy’s wagon Maverick model. It had already been hacked up a bit and front axle added.


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Old 11-22-2018, 07:59 AM   #3 (permalink)
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Sold the original drivetrain and picked up a Chevy 305, NV4500, atlas 2, high pinion Dana 60 front, 14bolt rear, and 42” pit bulls. Inspired by the “another chopped channeled Willy’s wagon” thread a few years back. Trying to keep as low as possible.


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Old 11-22-2018, 08:02 AM   #4 (permalink)
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Had a shop in Sacramento media blast the body and apply a ppg epoxy primer to protect. Got some rust spots to deal with but not too bad.


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Old 11-22-2018, 08:07 AM   #5 (permalink)
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Old 11-22-2018, 08:09 AM   #6 (permalink)
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Boxed the frame and started mocking up the suspension. Got parts from ruffstuff specialties, Dan is awesome to work with and his products are top notch. Had a buddy help with the 3 link front and 4 link rear.


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Old 11-22-2018, 08:13 AM   #7 (permalink)
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Did a little fender trimming, low as possible. Thinking 4 or 5” up travel on rear axle.


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Old 11-22-2018, 08:18 AM   #8 (permalink)
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Notched the frame to try and squeeze in the shock towers. Needs more gussets and gotta figure out some wheel wells. The stock ones won’t fit anymore.


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Old 11-22-2018, 07:40 PM   #9 (permalink)
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Subd! I've always wanted one of these...
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Old 11-23-2018, 08:43 AM   #10 (permalink)
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Had a shop in Sacramento media blast the body and apply a ppg epoxy primer to protect.
Who in Sac did your work? And if you don't mind, how much?
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Old 11-23-2018, 08:51 AM   #11 (permalink)
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Looks like you need a taller garage.
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Old 11-23-2018, 09:02 AM   #12 (permalink)
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Lil’John, I think it was BME or American Stripping Co. in Sacramento that did the blasting and primer. I think I paid $500-$700. TNT Powder coating in shingle spring has done some more recient work for me. Lance is easy to work with and quick turnaround time.


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Old 11-23-2018, 09:05 AM   #13 (permalink)
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Waterhorse, definitely outgrew that garage. We’ve since moved and now I have a 30’x40’ shop with 12’ ceiling.


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Old 11-23-2018, 09:24 AM   #14 (permalink)
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Removed toolbox and starting to remove Swiss cheese floors.


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Old 11-23-2018, 05:13 PM   #15 (permalink)
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Got a newer piece of sheet metal back in the passenger side, a little surface rust.


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Old 11-23-2018, 09:07 PM   #16 (permalink)
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axles

Looking good! Did you shorten the axles? Or do you know what WMS you're at?

Thanks
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Old 11-23-2018, 09:35 PM   #17 (permalink)
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I think they are (14 bolt) is 67.5” and (front 60) is 69.25” both uncut.


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Old 11-27-2018, 05:17 AM   #18 (permalink)
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I will be following this. I have redone a couple of them and frame swapped two. Looks great and I really like the size of the wagon. Just big enough to fit good size running gear etc. but small enough to fit through the trails.

Nice work. Looks great!
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Old 11-27-2018, 07:07 AM   #19 (permalink)
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Thanks, any tips or tricks you have from working on wagons would be greatly appreciated.


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Old 11-27-2018, 06:35 PM   #20 (permalink)
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Originally trying to set shocks like this....but that wasn’t going to work.

Some cut off wheels and plasma torch work to undo the frame French/notch.

Now maybe the shocks will fit better like this.


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Old 11-28-2018, 07:56 PM   #21 (permalink)
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Subscribed I always wanted to build on of these. Keep up the great work.
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Old 11-28-2018, 08:50 PM   #22 (permalink)
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I’m in. First real wheeling I did was in one of these.
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Old 11-28-2018, 08:55 PM   #23 (permalink)
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As 73FJ says circle the wagons! Always great to see another one coming back from the clutches of the crusher. Really dig the maverick model.
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Old 12-06-2018, 02:00 AM   #24 (permalink)
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So glad you are building it with a low COG as they look comical up high!
The new shock tower position will be much stronger than the large cutout in the frame you had too.
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Old 12-28-2018, 03:36 PM   #25 (permalink)
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Found some more shop time today. Packaging issues. Recessed the frame and mocked up tower. Full extension just barely clears. Can’t get full compression, tire hits shock. Might try a 1.5” spacer then get wheels with correct backspacing.


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