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

Got a few hours in last night and managed to modify the 37-41 spindles to accept the F100 front drums, they need 2 small mods the first being a bit of grinding to clear the back of the wheel cylinders, I will let the pics do the talking.


http://i65.photobucket.com/albums/h2...ps1qrzjtzo.jpg

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The 2nd modification is to allow the bearings to fit, on the early ford spindle there is a large radius fillet where the bearing sits, this needs reducing in a lathe so the bearing can sit flush.



http://i65.photobucket.com/albums/h2...psfhsipspw.jpg

http://i65.photobucket.com/albums/h2...psqbuthxnq.jpg




The spindle is chucked in the lathe and a revolving centre inserted in the machined centre on the back, then the radius is reduced to a small rad.



http://i65.photobucket.com/albums/h2...ps0bd0xjbq.jpg

http://i65.photobucket.com/albums/h2...pssvgb2jbq.jpg

http://i65.photobucket.com/albums/h2...ps76lgiu1a.jpg




Assembled



http://i65.photobucket.com/albums/h2...psiy0krr8i.jpg

http://i65.photobucket.com/albums/h2...psajiymoxe.jpg




All the parts I don't need at the moment will now go for media blasting and black powder coat.

Hopefully tomorrow I will drill the axle and adapt the spindles, looks pretty straight forward but we will see :rolleyes:

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Quote:

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Originally Posted by rspears

Steve, is Mr. Flap Wheel a bench grinder mount, something like this:

Attachment 60163

or do you use something else? Just curious...

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Roger I mislead you mate by saying flap wheel when I should of said flap disc, Your right in your post thats a flap wheel, sorry for the confusion.

This is the flap disc I use for most of my profiling.


http://www.arceurotrade.co.uk/imagec...c3_397x266.jpg

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"This is the flap disc I use for most of my profiling."

those work great for cleaning up and polishing

Awesome work! Another reason whay a metal lathe is on my list of have to haves. :LOL:

Here is another type of flap wheel for a die grinder. I love these for cleaning bores when doing ball joints, u-joints, newer hubs, wheel seals, etc. The link is just a reference pic. You can get these at a lot of different places and in different grits as well.

Mounted Flap Wheels | MSCDirect.com

Quote:

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Originally Posted by roadster32

Roger I mislead you mate by saying flap wheel when I should of said flap disc, Your right in your post thats a flap wheel, sorry for the confusion.

This is the flap disc I use for most of my profiling.

http://www.arceurotrade.co.uk/imagec...c3_397x266.jpg.

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Steve,
That's why I asked. I use flap disks for all of my profiling/grinding, in various grits, and I do not own a flap wheel but can see that they would be good for certain jobs. I've also seen the little shaft mounted flap wheels, both for a die grinder (1/4" shaft) and Dremel type driver but haven't used either.

Quote:

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Originally Posted by 40FordDeluxe

Here is another type of flap wheel for a die grinder. I love these for cleaning bores when doing ball joints, u-joints, newer hubs, wheel seals, etc. The link is just a reference pic. You can get these at a lot of different places and in different grits as well.

Mounted Flap Wheels | MSCDirect.com

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Yes Ryan I have lots of those too, we call that type a Drum flap wheel

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Quote:

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Originally Posted by rspears

Steve,
That's why I asked. I use flap disks for all of my profiling/grinding, in various grits, and I do not own a flap wheel but can see that they would be good for certain jobs. I've also seen the little shaft mounted flap wheels, both for a die grinder (1/4" shaft) and Dremel type driver but haven't used either.

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Roger the drum flap wheels are really handy for blending & fettling.

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Well I was glad to knock off a bit earlier today, been cutting, grinding & sanding the front axle for the last 6 hours !!! Now covered in black dust, started off bad this morning when I tried to remove the old brakes and spindles, kingpins were rusted in solid, enter Mr 9" grinder with cutting wheel fitted it made short work of the spindles & brakes, had to pop to my mates and press the remaining bits of kingpin out.

Next I set about cutting off all the lumps and bumps I didn't need, there were a fair few, a few holes were tigged up and then the mammoth sanding started !!!

Heres what I started with



http://i65.photobucket.com/albums/h2...psvk4eqpel.jpg




Heres how it looks now, next job is to set it up on the mill and bore out the kingpin hole as its bigger than the early ford so needs to be sleeved and reamed, then off to be media blasted as its easier than trying to clean out the middle of the I beam.



http://i65.photobucket.com/albums/h2...pshxqamajm.jpg

http://i65.photobucket.com/albums/h2...pspsor15lw.jpg

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A lot of work there, Steve, but a lot of sweat equity payback, too. Great to see how you turn a sows ear into a silk purse.

Quote:

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Originally Posted by rspears

A lot of work there, Steve, but a lot of sweat equity payback, too. Great to see how you turn a sows ear into a silk purse.

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Yes Roger it seemed to take all day to get it looking good, worth the effort for sure, the bath water was black !!!

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:3dSMILE: I bet Sue was overjoyed when you walked in like that too! So the axle is forged steel, right? What's the plan for it, paint, powder or chrome?

Quote:

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Originally Posted by rspears

:3dSMILE: I bet Sue was overjoyed when you walked in like that too! So the axle is forged steel, right? What's the plan for it, paint, powder or chrome?

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Yeah she wasn't to pleased as I was covered in grinding dust :LOL: Yes forged steel, its blooming hard work to grind !!!
Definitly not chrome on this one, Was thinking of trying out the chrome powder coat as its getting better all the time, or maybe just black powdercoat.

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Well today was gonna be a normal working day but due to the fact that the whole country appears to have shut down I thought I would do the same
Tried to get stuff from 4 different suppliers this morning and all closed till Jan 6th !!! No wonder the country is in a state

Anyway popped home and picked up the front axle and went to my mates engineering shop, hooray still there and beavering away the bridgeport was busy today so we used the Condor mill, lovely old bit of kit. Brians got 10 mills so we was spoilt for choice !!!

First job was how to hold the axle, Brian found a lump of I beam that fitted perfectly across the spring pads so we drilled holes and bolted the axle to the i beam, then the i beam was clamped down to the bed of the mill. next we laid over the head to 8.5 degrees (spindles are 9 but I want to run 0.5 negative) next the head was laid over in the other axis 4 degrees as the axle has 4 degrees of castor built in, next a suitable cutter was selected and the ends bored out.



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http://i65.photobucket.com/albums/h2...ps0308be60.jpg




Next we put in a fly cutter and straightened up the kingpin faces to the bore as the original bore was 7 degrees and the new spindles are 9 degree.



http://i65.photobucket.com/albums/h2...pspzuf3uwb.jpg




Next 2 sleeves were spun up in the lathe and press fit into the kingpin bosses.



http://i65.photobucket.com/albums/h2...psjfgbsamh.jpg




These were then reamed to 0.812" to produce a nice snug fit for the kingpins.



http://i65.photobucket.com/albums/h2...psnuj3u1tv.jpg




Fitted up with the hubs and viola we have a front axle assembly



http://i65.photobucket.com/albums/h2...pstyw32gj8.jpg


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Very nice work! Your measuring and ppolishing will pay off for sure!

ALL THOSE PRECISE ANGLES! IMPRESSIVE!(Dam caps lock button!) :)

Quote:

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Originally Posted by 40FordDeluxe

Very nice work! Your measuring and ppolishing will pay off for sure!

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Gonna put some holes in it next :D

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Quote:

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Originally Posted by stovens

ALL THOSE PRECISE ANGLES! IMPRESSIVE!(Dam caps lock button!) :)

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Look longer to setup than it took to do Steve

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Just wanted to wish everyone a very Happy Xmas and a prosperous New year

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Happy Christmas and New Year back at you guys. Hopefully you and Sue will have some Christmas Cheer.

Quote:

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Originally Posted by roadster32

Just wanted to wish everyone a very Happy Xmas and a prosperous New year.

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Same to you and your family! Tell Sue we said HELLO!

Well with xmas finally done and dusted i can get back into the workshop, heaven !!!
I got straight back onto the drilling of the axle that I had already started, all went well but I came across 1 hole that just won't drill no matter what I try !!! Its like a hard vein in the steel, I tried a brand new milling cutter but it just dulled the cutting edges, had it on the last one of these axles but managed to get all the holes done, I'm gonna pop to the machine shop tomorrow and see if my mate Brian has something to do the last hole.



http://i65.photobucket.com/albums/h2...ps6kolige8.jpg




This is the bit that won't drill



http://i65.photobucket.com/albums/h2...psnts0tbul.jpg

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That is some nice work! That's pretty crazy it won't drill. It'll be interesting to hear what he says on how to cut it. I've had semi axles that we had to drill for aftermarket air ride kits and we had these problems. We took the axles down to a shop that had a laser and they took care of them. That is not an option for this poor guy. :LOL:

Back when I was installing overhead cranes in factories or where ever they sent me we would occasionaly have that happen with the steel base plates. It was almost always with foreign steel. Seems there would be COAL in the steel you couldn't even torch it out with out much difficulty

We are going to try a carbide drill this morning guys, fingers crossed it will do the job

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Well Steve, if Brian can't get it for ya have your sign painter buddy paint a hole. With his talent it should be a snap!:D

Or just fill in the matching one on the other end :eek: :3dSMILE:

that's what I was thinking also-------------

Ah guy's have Faith! This is Steve we are talking about, he's resourceful and always figures these things out, making stuff way over our heads seem easy! Maybe drill int in stages with different diameter bits as he goes up in size?

Quote:

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Originally Posted by Bob Parmenter

Well Steve, if Brian can't get it for ya have your sign painter buddy paint a hole. With his talent it should be a snap!:D

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Ha ha ha, Hello Bob, havn't seen you around here for a while or have you been hiding :confused:

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Quote:

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Originally Posted by cffisher

Or just fill in the matching one on the other end :eek: :3dSMILE:

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Quote:

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Originally Posted by jerry clayton

that's what I was thinking also-------------

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Trouble is it would look goofy, can't be having that !!! :LOL:

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Thanks for the vote of confidence Steve, The other holes are drilled in various size stages but this one just wipes out the drill edges.

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Steve, is it feasible to apply some very localized heat to that hole center area without affecting the overall strength of the I-beam, and would that perhaps help?

Well the machine shop is shut today so the hole in the axle will have to wait, I've being getting bits and pieces made so when a bit of decent weather comes by I can attack this with a vengeance and get a rolling frame together in a day, Today i made up the firewall mounted brake pedal assembly.

Its all 1/4" BMS, could of got away with 1/8" but it just doesnt have the look.

Heres the main bracket



http://i65.photobucket.com/albums/h2...psum0smfib.jpg




Next spun up a phosphor bronze bush for the pedal pivot. Pedal is 1/4" BMS but with a 1/8" BMS stiffener, makes it into an I beam



http://i65.photobucket.com/albums/h2...psah2lalmc.jpg

http://i65.photobucket.com/albums/h2...pscobqnpzy.jpg

http://i65.photobucket.com/albums/h2...psxrb3yvc6.jpg




Heres the finished assembly, had to use the master cylinder of my 26T project as the one I ordered hasn't arrived yet.



http://i65.photobucket.com/albums/h2...psuorl9uxz.jpg

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Quote:

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Originally Posted by rspears

Steve, is it feasible to apply some very localized heat to that hole center area without affecting the overall strength of the I-beam, and would that perhaps help?

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Yes it shouldn't be a problem Roger, If the mega expensive drill don't do it we will try the heat, cheers for that.

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One quick fairly economical suggestion---------go to a hardware/lumber (USA Lowes, Menards,Home Depot) and get on of the specialty bits that they use for drilling granite counter tops------some are even hole saw type thingies with carbide cutters around the circle----but I would start out with the smaller 1/4 or so size

Quote:

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Originally Posted by jerry clayton

One quick fairly economical suggestion---------go to a hardware/lumber (USA Lowes, Menards,Home Depot) and get on of the specialty bits that they use for drilling granite counter tops------some are even hole saw type thingies with carbide cutters around the circle----but I would start out with the smaller 1/4 or so size

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Thanks Jerry, will give that a try if the carbide drill don't work.

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carbide ball mill or a spade drill .i would not heat it less you want to work hardened it a EDM will cut it as well as a diamond dip hole saw may work or a mounted stone grinding point on a die grinder and grind a hole . carbide ball mill will do it less glass hard then it diamond or EDM

I have some "die drills" I use when I have hard material to drill. They go through about anything.

In between working today i've been thinking about engine mounts, I really like the look of a front Hurst style mount, After I finished I hacked about a bit of plywood to get a rough shape, I picked up off the lower 4 timing cover bolts, they are 3/8", yes I know the centre hole is 1/4" off, I thought it was central between the 4 holes, it isn't, its 1/4" off

I think I may have it, next transfer to metal



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