Project: Tetanus Shot - 1948 Willys

More progress made today. I've been sick with the flu for the last few days but felt good enough today to spend some time in the garage. I picked up some hoses and a ram from @BigSouth a few weeks ago for hydro assist. I had an Astro box that was already tapped but it's got a reverse rotation. The other box I have is the correct box but it wasn't tapped. So I spent some time with a tape measure and some calipers and got everything marked up. Took longer to disassemble the box completely then it did to drill and tap. I've seen where people use grease on the drill/shop vac to remove steel chips but knowing my luck I would have gotten a lot of trash in the box. Both ports are now clean and tapped. The lower port is pretty much over the passageway which is perfect. Now all I need to do is reassemble the box, mount it, and figure out how to mount the ram and my steering should be complete.

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Steering box is back together and installed. Looking at mounting ideas for the ram. I'm running high steer up front and I'm SOA so really the only realistic point to mount the ram on the axle side is on top of the diff. I'm not really a fan of that but did stumble across this

Ram Assist Mount, 5" Tall | Hydro Assist and Stabilizer Mounts | WFOConcepts.com

I'm thinking I could mount this on the axle and "reverse" the ram and it should work really well. Any thoughts on going this route?
 
YJJPWrangler said:
Also, in terms of tie rod mounts I've seen both weld on and clamp styles. I think for adjustability I would like to use a clamp on style. Something like this?

Ruffstuff 1.50" OD Steering Tube Clamp

Anybody run these clamp style mounts? Pros/Cons? any slippage?
Click to expand...
I got this for my xj steering assist. Will be mounting it this weekend. I did clamp it to the tie rod and is a perfect fit, if it ever slips I'll just tack weld it. However with the fit, I think Ill be ok.
 
Not a whole lot done over the last couple weeks due to work, hunting trips, and working in the yard. I did manage to get the Solid diff covers installed that I picked up off the board, thanks @AdamH they fit perfect.

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Still need to get gear oil put in, any recommendations? I'm running Spartan lockers F/R. Any oil additives needed?

Started playing around with seat placement as well. I think my next step will be to build the main seat support so I can mount them. Im planning on tying the seat support into the cage. I think I have a good idea of how I want the cage to look but theres always room for options.
 
Got a little more done over the weekend. Got the steering cooler installed and starting to figure out how I want the lines to run.

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Also started working on some sliders for the jeep. They are 4x2x.25 wall rectangle tubing. There will be 3 frame mounts and it will tie into the cage design as well. No pics yet but they are coming along.
 
Just ordered the RuffStuff 1.5" Steering Clamp and the WFO hydro assist tower. Should have them next week or so...
 
Bringing this back to the top. The month of April/May was jam packed. Every weekend I had something to do so the Willys just sat. Just picked up a nice package from @Loganwayne with gauges, 4" brake lights, and some rocker switches. I'll be working on getting these hooked up to run off switched power but I did get one up and running tonight with some temporary wiring.

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I still need to order a speedo gauge and a fuel gauge but this is getting me in the right direction. I still need to weld on the hydro assist mount and get the steering finalized but its getting closer and closer. Just one step at a time.
 
Steering is about 95% done. After a lot of head scratching and measuring, I mounted my WFO hydro assist mount. I also was able to hook up my hydro assist ram to the box and plumb everything. Took almost a gallon of power steering fluid to fill it but I now have hydro assist steering. Still need to get some longer bolts and some misalignment spacers and then work out all the bubbles in the lines. Good news was I bumped the motor over to get the PS pump moving and the damn thing cranked right up after not running for a couple months so thats always a good thing.

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I'm pretty sure I need to shorten my drag link by 3-4" Right now I only have about 15-20 degrees of steering to the left. A shorter drag link would fix this. Pretty productive Sunday though.
 
Got the ram pulled apart today and pulled the spacers out.
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I had right at 6.25" of steering travel. I think this is as good as I'm gonna get. Now its a long process of bleeding the damn thing. No exhaust yet, so I'm forced to cycle the steering back and forth for what seems like eternity...

Waiting on a package from Barnes that has some goodies in it.

Also, I think this is how I want my cage to be, minus the double A pillar and I will be adding a X brace behind the seats.

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YJJPWrangler said:
Should I fill it up with the ram fully extended or fully closed?
Click to expand...

put your hose on the cyl. and stick the other end in the oil container. pull the rod out and fill one side. I suggest you also rotate everything with the engine off and spin that pump over by hand to be sure it's full before starting the engine. Excessive cavitation will kill your pump. so you want to get as much oil in the system as you can before starting the engine.
 
@Jeff B Sounds good. I think because I had to pull apart the cylinder, I introduced a ton of air into the system. Prior to pulling it apart I had it working pretty well but now its not. Every time I turn the wheel lock to lock, I get air bubbling out of the reservoir so I know its bleeding, just gonna take some time..
 
YJJPWrangler said:
@Jeff B Sounds good. I think because I had to pull apart the cylinder, I introduced a ton of air into the system. Prior to pulling it apart I had it working pretty well but now its not. Every time I turn the wheel lock to lock, I get air bubbling out of the reservoir so I know its bleeding, just gonna take some time..
Click to expand...

turn it one way and let it sit for 20 minutes or so, turn it the other way and let it sit for 20 min or so. Wait for all the air to bubble out before starting the engine. Spin the pump a little by hand to allow the pump to get oil through the vanes. It's time consuming but will save you from buying a pump. I also run AW32 hyd. oil in mine.
 
Still piddling around on this. Decided I needed to make more room in the garage in terms of storage. Got this setup last weekend

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With the new storage, I can technically fit both the Willys and the wifes Grand Cherokee in the garage BUT I wouldn't be able to walk around the Willys, much less open the toolbox so...the grand cherokee got booted and now the Willys is front and center in the garage. Wife isn't happy but understands and that gives me that much more motivation to finish the dang thing.

Also finished the driver slider install on Sunday. 4x2 tubing, 2x2 supports. Bolted to the frame and to the body for cage support. I plan on adding another plate to the in body mounts to sandwich the sheetwork. That should add enough rigidity to the body and make the cage easier to install/remove etc. Right now, the slider won't be a step but I'm planning on adding some tubing to the outside edge to create a step for it. First time doing it and I think it came out looking really good. Need some more material to build the passenger side and then its cage time.

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Stayed home today so our new AC systems could pass Meck county inspection and decided to finish up the passenger slider install.

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All bolted up and ready to go. Made some cage plates for the sliders to bolt to out of 1/4" metal. It was simple and easy work and I think they turned out well. Will give me a nice stable base to mount the cage too.

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Now just gotta get some tubing lined up and time to start building the cage.
 
Been spending more time in the garage. Trying to get at least 1 hour in each night and accomplish something as it usually tends to be the small things that hold up a project. Got the rear diff filled with Lucas 85-140 as well as the SM420. Filled it straight through the shift hole until it ran out of the fill plug. Easiest fluid change ever. Also got the shifter installed as well. It's a little high and will need to be rebent to clear the steering wheel but it will work for now. Went to the junkyard last friday and pulled a y-pipe for the exhaust. It fits the jeep although I did have to remove the front driveshaft.

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This is temporary exhaust. I'll need part of the Y pipe in the future once exhaust gets installed. For now, this will work and provide just a bit of back pressure as well as an oxygen sensor so I can tune the motor a bit more. The goal is to be able to drive it into the exhaust shop. I also got my brake pedal working. I still need to cut/reweld the actual brake pedal as the angle is wrong, but it pushs the booster/master cylinder now.

So whats left?
-Finish brake lines/bleed: I have the material to finish the hard lines. Will need to get two soft lines made to extend from the frame to the axles.
-Build cage/mount seats: Need to order some steel. I have the rough idea of how I want the cage to be and how to tie the seats in.
-Finish exhaust:
-Wrap up interior bodywork
-Finish electrical
-Build skid plate

There is probably a lot of other little stuff left that will eventually pop up. Goal for this week is to see if I can get it in gear on jack stands and the wheels turn.
 
This 1 hour a night is paying off. Got the rest of the hard brake lines plumbed and mounted. Just need to get some soft lines made and then its bleeding time. O2 sensor is hooked up and I tidied up all of the wiring and fuel lines in the frame rails. Tonight will be spent getting the transfer case mount welded to my crossmember. Should be a couple of tack welds in the jeep, then removal and fully weld. If I have time, I'll get the dana300 filled up and then its time to crank it and see if it goes in gear...
 
I use the "Do something" every night or at least 4-6 days a week on a project I'm working on. It makes a huge difference!
 
R Q said:
I use the "Do something" every night or at least 4-6 days a week on a project I'm working on. It makes a huge difference!
Click to expand...

It's insane how much I have gotten done this week. Wife is cool with it because it means I'm not gonna spend the entire weekend in the garage.

Last night I was able to pull the transfer case crossmember and get it fully welded up. Will reinstall it tonight. I also noticed that my SM420 was weeping oil around the side cover so I drained the new oil back into the jug, pulled the cover off and put some RTV on it. I've got a poker game tonight but if I get home early enough, I'll reinstall the crossmember, refill the trans, and try and fill the D300.
 
YJJPWrangler said:
It's insane how much I have gotten done this week. Wife is cool with it because it means I'm not gonna spend the entire weekend in the garage.

Last night I was able to pull the transfer case crossmember and get it fully welded up. Will reinstall it tonight. I also noticed that my SM420 was weeping oil around the side cover so I drained the new oil back into the jug, pulled the cover off and put some RTV on it. I've got a poker game tonight but if I get home early enough, I'll reinstall the crossmember, refill the trans, and try and fill the D300.
Click to expand...
I made big gains last night and am heading out shortly to make some more. Speaking of this I have got to start my own thread...but not right now I got stuff to put together!
 
Not much done last night because of the poker game(I broke even..:rolleyes:) but I was able to get the transmission crossmember reinstalled. It's was a little tricky but I managed to get everything fully bolted down. Today the plan is to fill the trans/transfer and get the rear on jackstands and see what happens.:popcorn:
 
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