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Discussion Starter #61 (Edited)
I bought them from Walck's, but everybody gets them from the same source; including Willys America and Kaiser Willys. There is only one guy making them. In fact, I think they all get them from Walck's. By the way, the rockers and rocker guards are very well done. Nice and straight and almost an exact match. They are worth the money.

I asked them what ever happened to the original dies for the front fenders, hoods, doors, sides, etc. and they said they were all melted down after production stopped. What I would give for a brand new fender or brand new hood. I know lots of other people would too. I also asked why they don't just do some repairs on the dies they have and they said it just isn't worth it to them. They only sell 20 of them each year for very little profit. Too bad they aren't in the hands of someone that really has a love of the old wagons and just wants to keep them alive.

Maybe we can all join forces and get a movie star or mega rich musician, or even a football player to help fund the development of some new dies!!! Now that would be SWEEEEEEET!!!!
 

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Man I cant believe the quality of those panels. PO cut the bodyline out around the rear wheel opening on mine and I was going to go the panel route too but not anymore. Build looks good I wish I could keep up with your build pace.
 

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Discussion Starter #63 (Edited)
Progress for today.

I built a custom bracket to mount my steering column, brake pedal, brake light switch, and hydroboost/master cylinder. It was quite challlenging. I had to build it to clear the hood hinges, pulley mechanism for the Willys wiper system and defrost vent.

I am very happy with the results.









View from the driver's seat. It feels perfect and tilts out of the way very well to make it easy to get in and out.


Once the firewall is in place, I will finalize the connections, add more braces, and install the hydroboost system. I built it so I wouldn't have to modify the brake rod length, which is nice. I used my CJ-7 pedal rather than the Tahoe pedal.




The linkage will exit the firewall nice and clean.




 

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for the rear axle just get some spacers/adapters to go to the right lug pattern and right width but still retain the stock brake setup. im sure you already have that in mind but thought id mention it

really nice build

wes
 

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for the rear axle just get some spacers/adapters to go to the right lug pattern and right width but still retain the stock brake setup. im sure you already have that in mind but thought id mention it
I don't know if things have changed, but I was never able to get a spacer to go from 6 lug to 5 on 5.5, or any 5 lug pattern.
 

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Discussion Starter #67 (Edited)
A-Dapt-It USA shows a 6 on 5.5 to 5 on 5.5 adapter, but it looks like it's only available in 2". They are $100 each.

A friend of mine here in Boise is a machinist. He has redrilled hubs and shortened/resplined axles for many of us and does a fantastic job. Very clean work. He's the one who machined down my front 60 hubs to 5 on 5.5. I will also have him drill and tap my flat top knuckles and build high steer arms. For the knuckles, machine work, and arms, he only charges me $250. That includes my own arm design specifications.

If only my project sequence would try to keep up with my changing mind, things would be much easier. I should have waited to buy wheels!! That is another option though. I could save these wheels and just buy new 6 luggers. All in all it might work out the same cost-wise and I end up with an extra set of nice wheels for another project. Hey, I only have 2 projects going right now. A 3rd would be awesome!!
 

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Discussion Starter #68 (Edited)
Well, tonight I figured out how to combine the stock Willys wiper pully system with the Tahoe wiper motor. It is definitely not an easy task.

I mocked it up using a piece of sheet metal as a firewall. I mounted the motor then modified the Willys center cable mechanism. I cut it apart and welded on a 4" tab. Then I just made a link between the two. It seems to be working very well so far. Now I will have delay wipers! And the only thing visible from the engine bay is the wiper motor, so it will keep things nice and clean.

I will try to post some photos of it once I get it done.

I am starting to get pretty excited as all the little things start coming together. I will work on the dash next. Gauge placement, light switch, heater/AC controls, vents, stereo, etc...

I saved all of the original rib sections from the original quarter panels. They were in pretty good shape. I am trying to figure out a way to integrate one or two of them into the dash. I want to find a good balance between modern and antique. It will be challenging for sure, but a lot of fun.
 

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Discussion Starter #69 (Edited)
Ok, well I finished the steering column bracket. I built it into a combination bracket that now holds the steering column, brake pedal, and master cylinder/hydroboost. The cool thing is that I was able to build it so I could use the original Tahoe brake light switch. It has 6 wires coming into it, so it's not quite as easy as the old style 2 wire switch. Now it plugs right into the factory Tahoe harness.

The brake pedal is my old Commando pedal, but I drove out the master cylinder pin and replaced it with the pin from the Tahoe pedal. I wanted to use the Tahoe pedal, but it had some pretty funky angles that weren't compatible. I also used part of the push rod from the Tahoe vacuum booster and welded it to the rod from my hydroboost. The pedal is a little high right now, but that's easy to adjust. Once I get the floor in I will dial it in.

This was a lot of work, because I built every piece from scratch.

I am very happy with how it turned out.













Tahoe brake switch installed






 

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Discussion Starter #72 (Edited)
Delay wipers on a Willys wagon. Well, now I have them.

Let me tell you, this is way harder than I though it would be. It took about 6 iterations to get it just right. The distance between the motor and the central cable pivot, the length of the arms and links, the angle of everything; tough sumbitch. But I finally got it.

I cut the cable pivot apart and used just the interior side of the mechanism, so everything could be under the dash. This took a while, but I want to keep the engine bay as clean as possible. The only thing on the engine side now will be the wiper motor.

Here is a photo of it.



And a little video. Sorry for the shitty quality. It's a cell phone video.

Wiper System Video

I had originally planned to eliminate the cable system and go to solid links throughout, but space is at a minimum under this dash. There just isn't enough room for it. Besides, I have to keep some of the originality.
 

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I have been following this build for a while, nice work. Kudos to you for hitting it hard and staying after it!!
What dimensions did you wind up with for the hole centerlines for the motor tab, and the pivot bar?
 

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Discussion Starter #74 (Edited)
I made major progress today.

I bought sheet metal for the firewall and floor and headed home to get to work.

Here is what I completed:

Firewall cut out and tacked in place
Steering column
Brake system (pedal, hydroboost)
Main heater/AC unit
Heater/AC fan
Wiper system

Firewall in place.



Heater/AC fan mounted





The suck side of the fan will pull air from inside the cab just behind the main heater/AC unit. There is a ton of room back there. At this time it will only work in recirculating mode. I just don't have the room to install the fresh air mechanism. But I will work on that later and maybe come up with something.



And the biggest news of the day! I got the wiper system completely done. It works SO awesome! The second I had everything hooked up I grabbed the wiring harness and plugged it in to the motor and column to see how it worked. It worked AWESOME!! I am so stoked about this!! Now that I know it all works perfectly, I will build a nice looking main link and clean everything up. It looks a bit clunky at this point.







Wiper motor mounted. I had to mount it right at the top of the firewall. It doesn't look like I will have any clearance issues with the hood. I put it on and it looked good from what I can tell at this point.



 

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Lovin the build. It's always good to see old iron being built to drive, and not just to be thrashed on the trail.
 

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Discussion Starter #76 (Edited)
Good Willys Build - keep it going! Now I almost wish I'd kept my wiper linkage. Reminds me of some very long days ( or nights? ) on my 51 PU which is overdue for some TLC but here's some motivation - cab forward is wagon-identical of course. This looks old-school because....it is...
Thanks Magnum. I have always liked your truck. How well does the tilt front end work for you? I have considered it, but the ones I have seen always seem to be floppy and loose. Would you do it again?
 

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Midnight, I can not imagine not having a tilt-front end - at least if you plan on keeping the rig for while. Working on the headers, radiator or pulling the engine is a breeze now - ( that 502 is a tight squeeze ). Never having to unbolt the grill from the fenders or fenders from the body is a real timesaver. I built mine with 1/2" pins that slide into poly-bushings in the cab so I don't get any floppiness.

That heater looks great. I finally added a Heater-craft unit in mine this fall - no AC though. I'm gonna delete my prior post so I don't clog up your build thread with my junk.
 

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Discussion Starter #79
Can you email or post me some photos of how you did it? I am totally with you on getting access to everything. And with my back being full of bolts, it's getting harder and harder to do everything.

I appreciate your insight on this. By the way, your photo and previous posts don't clutter up my build, they enhance it. I love looking at everybody's ideas and cool stuff.

Thanks in advance for any info you can provide.
 
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