Thread: Oh no not another Willys Gasser build, this time a Willys shop truck

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Not much done this week but I did get some exhaust mounts made, the pics will tell the progress, got the system done back to the rear wheel but need to decide now if I go side exit or out the back.
I went with a bolt in mount as it was easier. Had to enlarge the existing holes in the frame to 3"

















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Hell Steve, even your exhaust clamps and mounts are a work of art Sir... very good and , again, a great way for me to learn from a Master Rod Builder. It is all the little things that make or break a great looking car...

I know Watford is to the North of the Thames but I hope you are stil high and dry compared to some or many of your countrymen and women...

Originally Posted by Whiplash23T

Hell Steve, even your exhaust clamps and mounts are a work of art Sir... very good and , again, a great way for me to learn from a Master Rod Builder. It is all the little things that make or break a great looking car...

I know Watford is to the North of the Thames but I hope you are stil high and dry compared to some or many of your countrymen and women...

Cheers Whip, yeah we are high and dry at the moment, we are fairly high so don't suffer to badly

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A bit more progress while I wait for the laminator to do his thing, popped into my mate Brians engineering shop to use the folder to do an aluminium tank, got chatting and mentioned I had to make a pickup bed, why not do it now half hour later walked out with 2 x 16swg bedsides , Initially went with a 6 foot long bed but got home and tried it in place and realised a 5 foot would look better, so hacked a foot off, interesting little tip was that although the top angle looks to be 45 degrees its not, its actually 55 degrees.
To get the roll on the top was way to expensive so i ordered a length of 1" OD x 16swg bright CDS tube and will weld it in place, could be a tricky job !!!

Seriously thinking of bonding the stake bed pockets on instead of plug welding.







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Seem to have spent a lot of time today but very little to show for it !!! I bit the bullet and finished the tailpipes out the side, had to make a mount for it, bit simpler than the front mount, Got 2 rubber mounts up front so one is fine in the rear. just a piece of stainless bar scooped out to fit on the tube and drilled and tapped to take a old style Mini cotton reel mount. all bolt in for simplicity.














I also started to make an alternator mount but didn't take any pics, I was originally gonna stick with the original generator but I feel the alternator will be more reliable for a driver.

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Great work as usual! An older friend of mine makes bed sides just like the way you are planning to. Great job on those exhaust hangers, thanks for sharing.

Originally Posted by 40FordDeluxe

Great work as usual! An older friend of mine makes bed sides just like the way you are planning to. Great job on those exhaust hangers, thanks for sharing.

Thanks Ryan, glad your enjoying it

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It was like summer at the weekend so some progress was made, I ordered some tube for the bedsides and it arrived in time, I knew right from the start welding the tube to the top of the sides was gonna be a pain and also a 2 man job, so I got my mate Gary to help out, I like working with Gary as he knows what he's doing and dn't keep asking "why are you doing it that way "

First job was to get the tube tacked in place, it was cut longer than needed to allow for somewhere to clamp the ends. Welding 16swg sheet to 16swg tube is always a challenge as the tube tends to bow , Tig was out of the question due to the heat involved so we both decided to Mig and quench each weld as we danced around the joint.

We tacked it every 10" while checking with a straightedge first








Then clamped it to a piece of 2" x "2 box section, we were both convinced if we laid down 1/4" welds by dancing around in lots of different places and quenching with a damp cloth as quickly as possible every thing would be fine Here it is unclamped after cooling but when we checked it for straightness it had bowed very slightly , I can correct this with a touch of heat and a damp cloth later as it isn't too bad at all.








We decided on the other side to try and predict the bow by using a 1/4" packer in the centre and 1/8" outers and only clamp at the middle & ends, we used the same welding & quenching procedure, result was it came out perfectly straight when unclamped







Next job was to sand down the welds and metal finish it all.










Heres the bowed side and below the straight side










Here they are all metal finished and ready for the stake pockets to be welded on.










Next job was to mark out and drill the holes so the pockets could be plug welded in place










To protect in between the seams 3 coats of Epoxy primer were applied. then the pockets were clamped in place, and thats as far as it got until next time.







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Nice work Steve. You always make it look easy. Thanks for the extra detail shots of the process.

Originally Posted by stovens

Nice work Steve. You always make it look easy. Thanks for the extra detail shots of the process.

Cheers Steve. If it was easy everybody would be doing it

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Now I'm a bit confused, yeah, that was easy, I realize you build the coupe outside your home as you are with the pickup, so where is Sue's Roadster pickup while you are working in the garage ? And is Langys Hot Rod Shop at a different premises for the customer work you do ? What ever the situation is, you do absolutely brilliant work and I too appreciate you taking the time to photograph and explain to us how and why you do things. And now we know what pees you off in the workshop and we promise not to ask why, can we all be your helpers in the garage please.....

Dragged my Mig welder out tonight, use it very rarely these days, everybody wants to see Tig these days, Anyway plug welded the stake bed pockets onto the sides and sanded down the welds, it will need a thin skim of filler (gasp shock horror !!!) to sort it out straight as the sheet pulled around slightly.
I also went and collected the front panel we bent up that I forgot the other day, thats the next job to sort.







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Originally Posted by Whiplash23T

Now I'm a bit confused, yeah, that was easy, I realize you build the coupe outside your home as you are with the pickup, so where is Sue's Roadster pickup while you are working in the garage ? And is Langys Hot Rod Shop at a different premises for the customer work you do ? What ever the situation is, you do absolutely brilliant work and I too appreciate you taking the time to photograph and explain to us how and why you do things. And now we know what pees you off in the workshop and we promise not to ask why, can we all be your helpers in the garage please.....

Whip we have a single car garage on the side of our house which houses Sue's Roadster pickup, my domain is the large workshop at the bottom of our garden, we are an end house so have a side access to the workshop.

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Great work, what primer did you use? Is it brush on? Thanks for the great details here.

Originally Posted by 40FordDeluxe

Great work, what primer did you use? Is it brush on? Thanks for the great details here.

Ryan I just rollered on some epoxy primer to stop flash rusting from handling, it will get sanded and sprayed later.

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