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

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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

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

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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That's going to be a very cool front mount!! What'd your machine shop buddy find with the axle? Any word yet on how they solved the problem of the hard spot?

Originally Posted by rspears

That's going to be a very cool front mount!! What'd your machine shop buddy find with the axle? Any word yet on how they solved the problem of the hard spot?

Cheers Roger, its more or less done design wise although it may change slightly, Havn't had a chance to get to Brians shop yet as been a bit busy last few days, hopefully get there tomorrow.

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Well with Xmas & New Year out of the way normal sevice is resumed

The ply template was used as a guide for the plasma cutter, the edges were dressed and the various holes drilled, To ensure the centre hole was actually in the centre this time I turned up a piece of aluminium bar to act as a mandrel and drilled through the holes in the timing case and spotted the holes. To make it easier to remove a piece was cut out and replaced with a piece that bolts in place.








Next the chassis mounts were made up for the early ford style mounts, someone asked how the plate was bent around the outside, I just tack it in place and then just smack it around a piece of tube with a rawhide mallet and tack weld as I go, then finish weld inside & out and then linish smooth.


















Heres the finished mount ready to weld to the frame.







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Only got a few hours in the shop last night as had to pay a visit to the Osteopath at 4pm, came back but felt like I had been in a bar fight !!! I'm sure its done me some good though.

Anyway I tried to save the original front spring U bolts but the threads were knackered so found some stainless U bolts but they were slightly too short, solved the problem by turning up some barrel nuts.








Next job was to make up a bolt in front ladder bar mount, on the 16 chassis there are 2 chassis legs going back from the centre section, they are riveted in place so my plan is to drill out some of the rivets and use them to hold the plate in place, I will re rivet later.
First I made up the brackets for the front mount, they other side of the bracket will be the chassis leg.







Started to make up the main base plate in 3/16" steel but back started to seize up a bit so retired for the evening.









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Not got as much done as I would of liked today as had lots of customers popping in, first person to call in was Allan (53pop) but he came in handy as I needed someone to hold the ladder bars while I marked the base plate, thanks Al.

Thought I would post a pic of the frame centre section so it all makes sense.








Once I had a guideline it was back to the workshop to weld the brackets in place, the only piece of steel plate I had the right size was black so I expected to encounter weld problems, even after cleaning the black off it still don't tig weld that nicely for some reason ? the BMS is much nicer stuff.
First job was to get a 3" hole in the plate, a holesaw quickly did this job, next a piece of tube was spun to size in the lathe and welded into the hole with 9/16" sticking out to match the return I had planned, then the brackets were welded in place.








Next I added a return at the rear edge to stiffen the plate.










Here the ladder bars are temporarily bolted in place, they are 36" apart on the axle casing.









All I need now is one fine day and I should have a rolling frame with the motor mounted

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Well finally got the last hole in the axle sorted, It still didn't drill nicely and no matter what we tried it went off slightly, there seems to be a rock hard vein running through the steel, I've decided to live with it, nobody will ever notice









Had a slice of good fortune at the weekend as found my 56" wide rear axle casing wasn't gonna be wide enough with my 10" wide rear wheels and I would need a 58" case, Well I had ordered a new case from Curries for a customer but it had got dented slightly during shipping, Curries sent a replacement and told me to keep the old one, a couple of hours with a big fooking hammer and some heat saw it all straight again and its 58" wide










I had a few sets of Strange axles hanging around that Strange had delivered the wrong size (don't ask, its not unusual ) Armed with my trusty tape measure I found a pair that needed 1/2" trimming off the ends and they would slide into my case perfectly










Also found a 32 Ford aluminium radiator in my stash, its setup for a Chevy but I can adapt it to suit the ford motor easily, should keep the old Y block nice and cool.






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No body has that much stuff JUST hanging around. haha

Originally Posted by cffisher

No body has that much stuff JUST hanging around. haha

You do know what I sell Charlie ???

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The hole looks fine, not sure which one it was!

are you just using those bar ends for mockup?????