Thread: 41 Willys Gasser project

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Well the rain has gone for a while and the sun is shining again so managed to get a few things done.



After a bit of tooing and froing i think i have the hood just right.

















Made a template of the trans tunnel and then bent it up in a bit of aluminium sheet that was kicking around, I made a steel mounting flange that is screwed and glued to the floor and the tunnel screws to that with small countersunk machine screws.





















Managed to get the floor glassed into place as its a job done thats been bugging me. First i flipped the body upside down and trimmed off the lower sill return to 3/4" wide (this makes it easier to get the body on & off)

















Then the areas that needed keying were marked with a felt tip pen as its difficult to see where you have been with the white. Used and angle grinder and finger sander to key it.

































Next the floor panel was bolted back into place with 3 layers of mat & resin in between the flanges, then a further 3 layers were added at the top & bottom of the joints, Then 1 layer was applied to the underside of the floor.

















Once the resin had hardened the body was put back on the frame and matting cut to shape for the inside.

















As per the underneath everything was glassed in.

With that extra piece on the bottom did you have to pull the lower bottom of the car out each side to be able to lift the body up and off? As usual the workmanship is to your high standard,good on ya mate.

No mate, i put cutouts in to clear the body mounts, hows ya ailments these days ???

Originally Posted by Whiplash23T

With that extra piece on the bottom did you have to pull the lower bottom of the car out each side to be able to lift the body up and off? As usual the workmanship is to your high standard,good on ya mate.

Boy,
This project is sure moving along. Looking great as usual! Don Jr

We sure are glad you are posting again!
Keep up the great work and awesome documenting.

Steve you mentioned rain there. Is it typical this time of year? We are still getting poured on and it's June here in California! Very unusual weather. For me it keeps the projects in the crammed garage where it is impossible to work on them with out moving other stuff out into the rain! Yuck!
As Don said you've made some remarkable progress. It's funny seeing your talents don't just lie in metal fabrication, but cross over to glass too! Most people are good at one or the other but not both! How's the other project coming?

Thanks for asking Mate, I'm getting over the first knee replacement really well,got up to 110 degrees movement now and walking without the sticks so that part is all good. Now if I could get them to do my right knee,I would be happy as Larry. Hey I am so enjoying watching you work on this Willys,I don't mind not being out in the garage myself. Oh how about some updates and pictures on the T Coupe??

Hay Whiplash23T I had my right knee replaced April 1, 2 years ago Wish I'd had it done sooner. They had me up walking on it 2 hrs after surgery. They wanted 120 degrees and they got it real quick.. Dr. wouldn't let me drive till I got it. Sitting around ain't my bag.

Steve it usually is getting warmer around this time but we can get the odd shower, although the last 2 days its been more than the odd shower, we had hailstones 2 days ago !!!

Good to hear mate, i'm glad for ya. I'm still on the 26T but its engine building time and its gobbling up my Hotrod fund quicker than i would of liked !!!

Thanks Scott, I still have the occasional problem getting into the site but its much better now, why ??? I havn't a clue !!!

Cheers Dude, Can't wait to see you all, Hows Dad and Dan ???, Havn't heard from either for a while, I guess Dan is playing with his car and the old fella is chatting up the girls

Well in between the showers i managed to get the rear floor glassed in, I used a sheet of Bendy ply for this as the rear chassis kickup has an S shape in it and i wanted the floor to follow the shape, Bendy ply is made with the plys running the same way and this allows it to take very small radius's, you can order it to be bendy along the 8' x 4' length or sideways across.

First the shape was cut into the sheet and then the chassis was drilled and tapped 8mm, this was then bolted down with penny washers to keep it all flat.











Next the perimeter was glassed in and 1 layer put over the complete panel.








The ply only comes 8' x 4' and the body isover 4' so it was done in sections, here the rear section is in position but not glassed in as i ran out of resin










While it was pissing down i decided to make the various bits to fix the transmission cooler and 16" electric fan to the radiator, the fan brackets are made from 20mm x 5mm stainless bar, the trans cooler brackets are 16mm x 5mm stainless.

very nice work.....thats a lot of progress in a very short time.
well done

That's coming along real nice.
Gotta love that flexible plywood.