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

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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.

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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.

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

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

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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.

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








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.







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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.

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.

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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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?

Originally Posted by rspears

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?

Yeah she wasn't to pleased as I was covered in grinding dust 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.
















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.








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








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








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






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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!)

Originally Posted by 40FordDeluxe

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

Gonna put some holes in it next

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Originally Posted by stovens

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

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.