Thread: 41 Willys Gasser project

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It's amazing that you got those pipes to reshape like that, Steve. A few years ago we bought header flanges for Dan's 455 Olds and were going to make our own headers. When we tried making the round pipes large enough to fit the big square holes in the flanges, they kept splitting, no matter what we did. You make it look easy.

Don

Thanks for the compliment Harmon. Its appreciated.

Roger there is more room there than it looks, the bolts are about 1/8" away from the tubes, it will be TIG welded so the bead will be tiny where the bolts are, Or i might weld them on the inside as i have a tiny TIG torch that could just get in there.
The ports will be port matched to the headers so i had the flanges cut to exactly the shape of the port, if i put the tube inside it would spoil the gas flow.

The stainless bends are 316L Don, these are a little softer as they are annealed, this makes them easier to reshape, still takes a lot of hammering though.

Originally Posted by Itoldyouso

It's amazing that you got those pipes to reshape like that, Steve. A few years ago we bought header flanges for Dan's 455 Olds and were going to make our own headers. When we tried making the round pipes large enough to fit the big square holes in the flanges, they kept splitting, no matter what we did. You make it look easy.

Don

What a weird day today was, an hour of sun then a rain shower and then back to sun again, been like that all day, anyway during the dry patches my trusty helper Gomez came over to assist in sorting the rear windows as I needed 3 hands.



First job was to make a template

















Then the shape was transferred to the acrylic sheet and marked

















This is Gomez being humerous, little things please little minds !!!

















Next the holes were marked for the 3/16" button head screws, also the inner was marked & cut out.

















A quick check of the fit, all good.

















The template was clamped to the body and the holes drilled.

















Next the holes were transferred to the acrylic.

















Next the windows were bolted in. I was going to paint a black border around the window but i now have a better idea that will look like they are in rubber, stay tuned.



















The door & window handles are now polished.

















Also the hood is finally gapped, I think i have it right at last but may make the gap slightly bigger when i do the body work as i think its still a little tight to look authentic. Maybe someone with a steel Willys will be able to confirm the gap width ?

I think you will put a rubber extrusion around those windows with a little urethane to stop water leaks.

Steve very nice work on the hood supports, header pipes and the windows. You make it all look so easy! I'm enjoying watching this build very much.

I always enjoy watching the stainless twins' work too..I didnt think you would be allowed to use perspex for your windows Steve?? Us colonials arent allowed to..
Yep,I hope you urethane those windows in,specially with your weather patterns..
You can tell where our influences come from...

Something similair Whip, I have a cunning plan

Glad your enjoying Steve, I certainly am

Yes Robin they will be sealed, can't do it yet though till its painted. Perspex ok but not for front screen.

Been playing with ideas for a black border around the windows.

Black border looks good.
Did you apply weather stripping foam to the lip?

No mate thats my template painted black to see what it looked like. just a mock up

Last night i made up some trims for the rear windows to give the appearence of rubber trim, Looks much better.