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

The door inners are now pretty much there now which left one last job before I start putting metal and windows in, the job was to put in a return to mount the whisker strips onto, this is one job I always do on a glass car as looking in the window opening there is nothing worse than seeing the door inards, it really spoils any nicely built car.
So around the opening was keyed up and I mixed up some chopped mat and resin, I call it strawberry but its also known as bridger, its basically small chopped fibreglass strands mixed in resin to form a paste, its very handy for certain jobs.



http://i65.photobucket.com/albums/h2...ps9ofy2uqa.jpg




Next I started installing the window channel, to hold the channel I split a piece of 20mm x 1.6mm box in half which gave me 2 10mm deep channels, the felt window runner is a nice snug fit in this.



http://i65.photobucket.com/albums/h2...psbuxfx2dj.jpg

http://i65.photobucket.com/albums/h2...psteormk6g.jpg

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Next I cut some 5mm ply to shape as a window template and formed the felt channel around it.



http://i65.photobucket.com/albums/h2...psse6yebmi.jpg

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Thanks for posting this detail, Steve! Looking forward to the next installment.

Like Roger said, great details on this. I really like the idea of splitting that tube to hold the felt.

A bit more progress, started framing up.



http://i65.photobucket.com/albums/h2...psq9bs5gab.jpg

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Quote:

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Originally Posted by 40FordDeluxe

Like Roger said, great details on this. I really like the idea of splitting that tube to hold the felt.

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I was gonna form it Ryan but I just looked at the box section on the bench and it seemed the obvious route to take.

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Quote:

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Originally Posted by sharpmark

pretty impressive build thread and your work looks first rate!
thanks


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Thanks Mark.

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Love it,Steve.. Looking good.. Gotta admit,,I never thought about using a 20mm box for that job..I have used a 20,or 25x 12mm ( I think),with one side cut off for a snug fitting window channel though.. The glass dropped into well..

Bit more done to bore you all

I usually like manual window winders in an old car but as I didn't have any VW winding mechanisms in stock I decided to use some electric units I stock, I guess as I sell and endorse these kits I really should use them as well !!!

First job was to modify the top mount as it wasn't how I wanted it, Chopped it off and welded my version on.



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




I modified the bottom mount to my liking also, all the holes are drilled 1/4" while I set it all up then I drill out to 3/8" to allow a bit of adjustment in all directions.



http://i65.photobucket.com/albums/h2...pszv4e8ul1.jpg

http://i65.photobucket.com/albums/h2...psbzdlfz5o.jpg




I also fixed a steady for the motor



http://i65.photobucket.com/albums/h2...psr9x68dc6.jpg




Heres the mechanism in place, Its really a great little kit that works great, comes with switches & wiring harness but I won't be using them as I don't want the look of modern switches.



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




This is a shot of the clamping system, A great idea that works



http://i65.photobucket.com/albums/h2...ps6clnvmef.jpg




The top limit relies on the bracket I cut off so I spun up a buffer in the lathe for the end of the travel. also clipped up the exhaust tube.



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

http://i65.photobucket.com/albums/h2...ps931yjuxe.jpg




Heres what i'm using in place of the modern rocker switches, they use micro switches for up & down action, i'm using 34 ford winder handles, modern windows with an old look.



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

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

http://i65.photobucket.com/albums/h2...psgiqea5ns.jpg




Here the switches are mounted in simple brackets.



http://i65.photobucket.com/albums/h2...psn3wc9xtg.jpg

http://i65.photobucket.com/albums/h2...pst05eudbl.jpg




Next job was to bond in the window channel, using Polyeurathe Adhesieve Sealant, sticks anything like shit to a blanket !!!



http://i65.photobucket.com/albums/h2...psr2expfp0.jpg

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




I found these door actuators on my shelf and they are just the right length and will take the 34 ford handles perfectly. Locks are some slim bearjaw locks I had kicking around.



http://i65.photobucket.com/albums/h2...psrncabs4s.jpg

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

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Very very nice work there Steve and you have made me rethink the way I am building the doors for the Bucket re frame wise, and I don't have windows to worry about. Thanks so much for taking the time to not only photograph what you are doing but your easy to understand explainations is so helpful, it is brilliant.

Had to knock off a bit earlier today as we have friends coming but I did get the windows all going up & down nice & smoothly
Also I knew space was tight for the bearjaw locks so had to form a slight bulge in the door jam to accommodate them, it will also make life easy for prospective customers as its a standard lock I keep in stock.

Hers a few pics and a short video



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



Video

https://www.youtube.com/watch?v=iV4EUvylKj4


Heres the whisker trim and where it will fit



http://i65.photobucket.com/albums/h2...ps5foojv5t.jpg




Here the lock position and the bulge I formed, all done with a bit of shaped wood and masking tape



http://i65.photobucket.com/albums/h2...ps8bb63fvn.jpg

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

http://i65.photobucket.com/albums/h2...psnnsptsh5.jpg

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

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Quote:

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Originally Posted by Whiplash23T

Very very nice work there Steve and you have made me rethink the way I am building the doors for the Bucket re frame wise, and I don't have windows to worry about. Thanks so much for taking the time to not only photograph what you are doing but your easy to understand explainations is so helpful, it is brilliant.

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I'm glad it helped you Whip, makes it all worthwhile :cool:

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I got the lock in last night, space was pretty tight. I also got the handle actuator sorted also



http://i65.photobucket.com/albums/h2...psjagye0zk.jpg

http://i65.photobucket.com/albums/h2...ps5rnogbb7.jpg

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



There is a plate that ties the lock into the frame which the nuts are welded to, forgot take a pic.



http://i65.photobucket.com/albums/h2...psrrpo6jhc.jpg

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

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http://i65.photobucket.com/albums/h2...psmsns4zth.jpg

http://i65.photobucket.com/albums/h2...pss3buj48b.jpg


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More progress, nearly there. I splashed some black epoxy on the inner last night to tidy it up and just fitted it up after tea, next job is to fit the striker on the door jamb and mount the outer door skin & outer handle.
Someone mentioned the raised door lock, they suggested it might catch the door jamb when opened :o It won't because its only raised 5/16" and the jamb has 1/2" of clearance :D

Hopefully tomorrow night the tinted acrylic will be here so I can fit the proper window :cool:



http://i65.photobucket.com/albums/h2...psxzeezj9j.jpg

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I can now get on with the next job fitting the outer handles as the Willys repro handles I ordered turned up today, They are specially made for glass bodys as the original Willys handle fits with a clip arrangement that doesn't work on glass bodys. Also my tinted acrylic showed up so need to cut that to shape also.



http://i65.photobucket.com/albums/h2...ps0bvozfn4.jpg

http://i65.photobucket.com/albums/h2...psm58pn5ig.jpg

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Last night saw the handles fitted, they operate stainless steel bicycle cables.

First thing to sort was the handle pad on the doors, the doors have the 1940 round pad but the handles are only available 41 shape so I had to build up the pad with GRP chopped paste.



http://i65.photobucket.com/albums/h2...psaox4brqv.jpg

http://i65.photobucket.com/albums/h2...pso9ufhver.jpg

http://i65.photobucket.com/albums/h2...psc8amz5vv.jpg




Next I prepped the inside for the strengthening plate I had planned, I personally wouldn't fit the handle without a plate behind. The plate is 16swg aluminium, I spun up a piece to hold the outer cable and a bit more 1/8" plate for a riser, I did it aluminium for no other reason other than I don't weld much aluminium and fancied a change.



http://i65.photobucket.com/albums/h2...psej3f0ohx.jpg

http://i65.photobucket.com/albums/h2...psz3q3aajz.jpg

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




Next I needed a actuating lever to fit the 5/16" square bar on the handle, this was made in a bit of 3/8" plate and is secured to the square by a grubscrew.



http://i65.photobucket.com/albums/h2...psn0nmxxxr.jpg

http://i65.photobucket.com/albums/h2...ps4oiyhele.jpg




Here its all assembled and glassed into place. I bonded in a couple of bits of aluminium tube for the cable to run through so it don't rub against the window.



http://i65.photobucket.com/albums/h2...pstinw3mox.jpg

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

http://i65.photobucket.com/albums/h2...psvgyajtx0.jpg

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