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Tech => Projects => Topic started by: workgoats on July 26, 2012, 11:16:20 PM

Title: Willyreplica from the start...
Post by: workgoats on July 26, 2012, 11:16:20 PM
I tend to want something different.  So...

I started with a fairly good looking 89 Cherokee.  The engine was toast.  We bought it for the transmission which was transplanted into my daughter's 88.

(http://workgoats.com/images2/img_1-17-2012_02_500X375.JPG)

I built one of those fancy devices to rotate a vehicle around so you could easily work on the bottom.

(http://workgoats.com/images/img_2-1-2012_05a_500x328.jpg)

When I got through cutting on the XJ, this is what I ended up with.

(http://workgoats.com/images/img_2-2-12_06a_500x374.jpg)

I built the beginning of the frame with 2x3 tubing.  There will later be a 2x2 tubing frame member that the floor is bolted to.

(http://workgoats.com/images/rolling_frame_1_500x375.jpg)

The engine is a 318 that was removed from a running Ramcharger to make room for a Magnum 360.  The transmission is a 904 built from a 2x Ramcharger front case and the balance from a 80's Eagle SX-4.

(http://workgoats.com/images2/img_0008_500x375.jpg)

The transfer is a NP242 from the 89 Cherokee.  The input gear had the wrong spline count for the Eagle transmission but Novak people provided the right one.

(http://workgoats.com/images/transfer1_500x375.jpg)

I did a final square up on the frame and welded a piece of 1/8" plate above the rear axle and the shock mounts to hold it where it belonged.

(http://workgoats.com/images2/3-19_01_500x375.jpg)

I had in mind what I wanted it to look like.  The plan is to get a Texas title for a Willys replica.  I went as far as putting up a concept drawing and lined out a plan for the grille.

(http://workgoats.com/images/concept_1_500x279.jpg)

(http://workgoats.com/images/grille1_500x321.jpg)

After the frame was established, I centered my time on fabrication of the grille.  I planned it to look like a 1948 +/- Willys but I changed the number of vertical bars.

(http://workgoats.com/images/grille2_500x375.jpg)

I first thought it would sit on top of the front cross member but it was too high.  I was too hard headed to redesign so I modified it a little and mounted it 6" lower.

I found headlight buckets in a couple of old Dodge pickups.  One came from a 1953 3/4 ton stake bed and the other from a 1955 half ton pickup.

(http://workgoats.com/images/grille3_500x375.jpg)

(http://workgoats.com/images/grille4_500x375.jpg)

The vertical bars are light weight 1" square tubing.  Modifications to the grille continued.  Part of the front fenders are welded to the grille and bolted to the remainder of the fender, allowing removal of the front end (for when I install a bigger engine).

(http://workgoats.com/images2/3-31_02_500x375.jpg)

The parking lights came from kaiserwillys.com (http://kaiserwillys.com).  That is the same source I used for the CJ instrument panel that I bought.

The radiator was purchased from Speedway and it was a tight fit.  I will next post info about the completion of the grille and installation of the radiator.
Title: Re: Willyreplica from the start...
Post by: workgoats on July 26, 2012, 11:20:09 PM
The grille wasn't sturdy enough at first.  When I added the fender extensions it helped a little.  After the fenders were built, I filled in the inner fenders and added some structure to the back of the grille assembly.

(http://workgoats.com/images2/4-7_02a_500x322.jpg)

The radiator had to go so far up in the grille assembly that I had to make a little door for access to the radiator cap.

I built a base for the battery...

(http://workgoats.com/images2/4-7_03_500x375.jpg)

...and hooked up the power steering.

(http://workgoats.com/images2/4-7_04_500x375.jpg)

The seats are several inches rear of normal location for a XJ.  The steering shaft was completed using a 1996 Dodge 1500 steering shaft, a pillar bearing and half of a Cherokee shaft.  The pillar bearing was attached to the inner fender to help provide clearance around the exhaust manifold on the 318.

(http://workgoats.com/images2/4-1_01_500x375.jpg)

(http://workgoats.com/images2/4-1_02_500x375.jpg)

(http://workgoats.com/images2/4-1_03_500x375.jpg)

The bearing and a u-joint are prety close to the exhaust manifold.  I plan on placing a heat shield between them before it hits the road.

I had been busy, the plant was shut down, and I had lots of time but no income...

With the flat floor, the shifter  needs to be raised up to reach it.  I started here with a surplus electrical enclosure panel.  The entire truck is made from these.  I measured and marked the pieces for the shifter base.

(http://workgoats.com/images2/4-12_01_500x375.jpg)

I cut the pieces out, using my soon to be history Harbor Freight grinder.  (It has really lasted a while.)

(http://workgoats.com/images2/4-12_02_500x375.jpg)

In order to get the mig welder to weld decent, the paint has to be removed from the immediate area of the welds.  I removed it with another Harbor Freight grinder and a sander wheel.

(http://workgoats.com/images2/4-12_03_500x378.jpg)

Nick was there and he helped align the pieces.  My welding looked like this.

(http://workgoats.com/images2/4-12_04_500x372.jpg)

After it was dressed up (welds ground smooth) the shifter was bolted to the top and it was welded to the floor panel.  I left it at this point and will come back in a day or two to hook the other end up to the transmission.

(http://workgoats.com/images2/4-13_01_500x381.jpg)

To show that I am really working on it, here is where I stopped tonight on the dash.  I have some stuff to do tomorrow to help the other half out, but with any luck at all, the gauges and speedometer will all be mounted and dash wiring started.

(http://workgoats.com/images2/4-13_02_500x375.jpg)

(http://workgoats.com/images2/4-13_03_500x375.jpg)
Title: Re: Willyreplica from the start...
Post by: workgoats on July 26, 2012, 11:27:30 PM
I managed to get it outside for the first time on April 14th. (I had started about the first of February.) 

It may not look like much has been done, but I have been working on it.  I had to remove the floor and add bracing for the seats when I determined where they would sit.  I've also spent a bunch of time on wiring.

(http://workgoats.com/images2/4-14_01_500x372.jpg)

There is still a bunch of grinding to do.  I don't even want to think about painting.

(http://workgoats.com/images2/4-14_02_500x406.jpg)

It won't be long before all the wiring is ready for startup.  I'm working on stuff behind the dash now.

(http://workgoats.com/images2/4-14_03_500x375.jpg)

The dash is in place and a bunch of wiring has been done since these pics were taken.

(http://workgoats.com/images2/4-14_04_500x375.jpg)

(http://workgoats.com/images2/4-14_05_500x375.jpg)

I really need to get something in the back to hold the rear axle down.  (gas tank, roll cage,  spare rack,  tool box,  rear bumper, hitch...)

(http://workgoats.com/images2/4-14_06_500x375.jpg)

The following pictures were taken on April 19th.  Moving along at a regular pace.

(http://workgoats.com/images2/4-19_01_500x375.jpg)
(http://workgoats.com/images2/4-19_02_500x375.jpg)

Theses pics were taken on April 29th.  I had been working on the shifters and transmission cooling lines.  I added some on the roll bar.  Thought was, "One more cross piece toward the back and I will call it quits before Ram Jam."

(http://workgoats.com/images2/4-29_01a_500x292.jpg)
(http://workgoats.com/images2/4-29_02_500x375.jpg)
Title: Re: Willyreplica from the start...
Post by: workgoats on July 26, 2012, 11:43:56 PM
It doesn't look much different from previous pictures but I had done a lot.  I managed to drive it out of the garage on May 18th and turned it around.  It went forwards and backwards.

I found that the one wheel cylinder that I elected not to replace will still get to be replaced.  Should have done it to start with.

I had a transmission pan leak.  The pan was damaged and a new one was scheduled to be delivered the next day.

I had removed the back seats from the red truck to have room for Ram Jam stuff and will be installing the seat belts from them for Ram Jam.  I have another set coming to replace the borrowed ones.

I have also installed a compressor for on board air but it doesn't have any oil in it so it will just serve as an idler for the alternator belts.  Also, there isn't a tank yet.  I have the idea that it could be used with a portable tank plugged into the quick connect fitting.

And YES, it needs larger tires and doors and a hood.  It will get them all some day.

(http://workgoats.com/images2/5-18_06_500x375.jpg)

(http://workgoats.com/images2/5-18_02_500x375.jpg)

(http://workgoats.com/images2/5-18_04_500x375.jpg)

On May 25th the build hit a snag.  After replacing the front axle u-joints I went to turn the thing around and work on the back bumper.  The transmission blew up before I could get it out of the garage.  This ended the possibility of making it to Ram Jam with the Jeep.  And by this time I considered it a Jeep, a Dodge powered Jeep.

After Ram Jam I started tearing down the rig to replace the broken transmission.  Here is what I found when I removed the floor.

(http://workgoats.com/images2/6-13_01a_500x312.jpg)

It does certainly appear that the malfunction is in the transmission...

A recap:  This transmission was a 904.  The case is from a mid-80s 2x RC.  The innards are from an 82 or 84 Jeep Eagle SX-4.  I put it together years ago for a project that got cancelled.

I set out to put this on a 318 and to install a 242 transfer out of a Cherokee.  The Jeep transfer had the wrong spline count to match the transmission and I changed the input gear to match the spline count on the tranny.

Here are the comparisons between the 904 and the 727.  There is not much length difference in the transmissions themselves, but the adapters are quite a bit different.

(http://workgoats.com/images2/6-13_03_500x431.jpg)

I found parts of the governor in the driveway and felt that was what cratered.  Here is what it looked like when I pulled the adapter off the end of the 904.

(http://workgoats.com/images2/6-13_08_447x500.jpg)

I think this cratered because I did not check the differences between the Jeep parts and the Dodge parts.

Here is the adapter end of the Jeep transmission, followed by the end of the Dodge transmission.

There is a big difference between the distances.  The Jeep adapter is much shorter and has a seal after the governor.  The Dodge is over 2 inches deeper and does not have a seal. 

(http://workgoats.com/images2/6-13_04_500x394.jpg)

(http://workgoats.com/images2/6-13_05_500x407.jpg)

The input gear that I installed in the transfer case had the right spline count but may have been too long.  The parts of the governor did not show any contact with the gear and there are no scratches on the gear but it might have had something to do with it.

Here are pics of a 208 and the 242 after I have installed the new gear.  There is a bunch of difference but I do not have the transfer that originally came on the Jeep transmission so I don't know what it looked like.


(http://workgoats.com/images2/6-13_06_500x381.jpg)


(http://workgoats.com/images2/6-13_07_500x425.jpg)


It appears to me that the 242 will fit on the Dodge adapter without any conflicts.  The spline count is correct and the bolt pattern is the same but I will be measuring for interior clearance at least 4 times before I put the two together. ??? (http://ramchargercentral.com/index.php???)
Title: Re: Willyreplica from the start...
Post by: workgoats on July 27, 2012, 12:00:01 AM
The 904 transmission is now replaced with a 727.  The adapter is much longer and ended up raising the transmission and transfer about an inch.  The transmission is larger in the bellhousing area too. So, I ended up removing flooring and structure as well.

Here's what it looked like when I got ready to start back with the floor.

(http://workgoats.com/images/6-20_01.jpg)

I have already spent at least a day rebuilding the transmission shifter.  I am using the shifter from the 89 Cherokee.  I had to approach the transmission from the wrong direction but it didn't make a lot of difference because the Jeep transmission (4 speed) and the 727 have different throw lengths and it would have taken a bell crank of some sort even if I wasn't changing direction.

Following is a bunch of pics showing the transformation from open floor to the most elaborate transmission hump you can imagine.  Sorry for all the pics but it shows my limited mind....

(http://workgoats.com/images/6-20_02.jpg)
(http://workgoats.com/images/6-20_03.jpg)
(http://workgoats.com/images/6-20_05.jpg)
(http://workgoats.com/images/6-20_06.jpg)
(http://workgoats.com/images/6-20_08.jpg)
(http://workgoats.com/images/6-20_09.jpg)
(http://workgoats.com/images/6-20_10.jpg)
(http://workgoats.com/images/6-20_11.jpg)
(http://workgoats.com/images/6-20_13.jpg)
(http://workgoats.com/images/6-20_17.jpg)

There is one little space against the firewall that will eventually need a little backing as I cut out too much when I enlarged the hole for the transmission.

By the way, I don't need any comments on my tack welds...
 8) (http://8))
Title: Re: Willyreplica from the start...
Post by: workgoats on August 13, 2012, 09:31:07 PM
They have been making fun of me and my vehicles on RCC.  Maybe I should buy myself some more goats....

I picked the color for the rig today and will try to upload a pic.  Our internet is having problems so it might not make it.
Title: Re: Willyreplica from the start...
Post by: crazzywolfie on August 13, 2012, 11:45:38 PM
that is pretty cool. i like that color of blue.
Title: Re: Willyreplica from the start...
Post by: workgoats on September 09, 2012, 06:26:53 AM
So, to cure the motor mount / differential top control arm contact, I decided to raise the front a little and make it stiffer.

You will have to pardon the pic quality in these.

Here is the before pic with the suspension all the way down.

(http://workgoats.com/images2/x_before.jpg)

SixGun helped me secure a set of springs from a Grand Cherokee with a V-8.  We don't really know if these are stock springs or not.  They are stiffer than I expected.  Here is a pic of one of the original springs and one of the replacements from the Grand Cherokee.

(http://workgoats.com/images2/x_springs.jpg)

The springs may be a little larger in diameter but they do have an additional coil in the save distance.

I had a fear the height was not enough so I decided to add an inch of spacer.  I found a guy who had done this before and I did something similar, starting with a couple of cutting blocks bought from the grocery store.

(http://workgoats.com/images2/x_spacer1.jpg)

The center holes were drilled out with a hole saw and the outside cut with a jig saw.  The circle drawn in between is the amount that has to be beveled out to fit the spring tower.  I beveled it out with a dremel tool.  It was down and dirty.  I may never get all the plastic stuff out of the garage.

(http://workgoats.com/images2/x_spacer2.jpg)

Here is what it looked like when I got it all back together. 

(http://workgoats.com/images2/x_after.jpg)

Total lift at the front was 2 1/2 inches.  That was actually what I was hoping for.  After getting it back out on the street, I have decided not to lift the back now.  I like the way it sits now.

I don't know about the function of the front sway bar.  I have custom mounted it to both clear and protect the bottom of the radiator.  Both links sheared when I took it loose so I have rebuilt the links and lengthened them a little.

I also added a 2" extension to the bump stop to be sure the axle does not make contact with the motor mount.  I made that with 2" pieces of tubing and a washer welded to each end.  One has a nut welded inside and the other has a bolt.  I screwed the extra two inches in and then screwed the original bump stop into the extension.

You can see the extension in the after picture.  I drove it over some dips in our street but it hasn't had a real test.  I have a tow bar on it today and this afternoon I will take it to where I work.  We have a driveway about a half mile long and I intend to drive it back in forth long enough to see how the radiator holds up.  We also have a couple of gullies and I might see what it will do off the road a little.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on September 09, 2012, 04:16:51 PM
what color blue is that? I like it.
Title: Re: Willyreplica from the start...
Post by: workgoats on September 09, 2012, 04:32:51 PM
Quote from: rjtx667 on September 09, 2012, 04:16:51 PM
what color blue is that? I like it.

I don't remember but I will look it up.  The more I think about colors, the more I like olive drab.... :dontknow: (http://:dontknow:)
Title: Re: Willyreplica from the start...
Post by: SixGun on September 09, 2012, 11:00:40 PM
Quote from: workgoats on September 09, 2012, 04:32:51 PM
I don't remember but I will look it up.  The more I think about colors, the more I like olive drab.... :dontknow: (http://:dontknow:)

:PDT_Armataz_01_37:  Olive Drab and Willys naturally go together.
Title: Re: Willyreplica from the start...
Post by: workgoats on September 16, 2012, 07:22:45 PM
I have installed a tow bar in order to haul the project out to where I can do a little test driving.  I will design some "D" links that will attach to the tow points for extraction (although it shouldn't be needed).

(http://workgoats.com/images/09-16_01.jpg)

I have basically finished the structure for the hood.  It is hinged from the left fender.  I expect to skin it later this week with a fiberglass panel and pop rivets.  It can be re-skinned with sheet metal later if needed.

(http://workgoats.com/images/09-16_02.jpg)

(http://workgoats.com/images/09-16_04.jpg)

I still have a lot of grinding to do, especially around the window frame.  I have to have the front driveshaft rebuilt and a windshield installed.  I WILL be ready for Hidden Falls in October.
Title: Re: Willyreplica from the start...
Post by: DerangedMoose on September 17, 2012, 11:00:34 AM
This thing is awsome. :thumbsup:   great job.
Title: Re: Willyreplica from the start...
Post by: workgoats on September 30, 2012, 10:29:34 PM
I have begun work on the doors and the hood again.  Here is what the door opening looked like before I started.

(http://workgoats.com/images/09-20_01a.jpg)

(http://workgoats.com/images/09-20_02a.jpg)

The doors will be framed with light weight 2" square tubing.  I will also put a 3/4" square tube around the sides and bottom to allow for a lip to seal against another 3/4" tubing attached inside the opening.

(http://workgoats.com/images/09-20_03a.jpg)

With the 3/4" tubing tacked around the sides and bottom, I installed spacers and clamped the pieces in place to be tack welded and then removed to be welded up.

(http://workgoats.com/images/09-20_04a.jpg)

(http://workgoats.com/images/09-20_05a.jpg)

I have temporarily skinned the door with fiberglass (FRP) panel and installed the tubing in the door opening.  I have attached hinges as well but have a clearance problem with the steering wheel.  I made the body so narrow that the steering wheel is  too close to the door.

I think I can solve that problem but it won't happen till tomorrow.  I will post pictures on that too.  (when I remember to take them)

I took a sheet of the FRP and cut it closer to size for the hood skin.

(http://workgoats.com/images/09-30_01a.jpg)

If you are not familiar with the term FRP, it is a fiberglass panel used in bathrooms and many commercial kitchens.  It is 1/16" thick and textured on the front.  I have turned the textured side inside and using the flat, back side for the skin on the hood.

After installing enough rivets to insure the clearances would not change on the hood, I pulled the hood and began to work from the center toward the edges.

(http://workgoats.com/images/09-30_02a.jpg)

I managed to get one side basically completed and rough trimmed to the framework before I had to call it a day.  Hopefully I can get back on both of these project areas tomorrow.
(http://workgoats.com/images/09-30_03a.jpg)
Title: Re: Willyreplica from the start...
Post by: rjtx667 on October 02, 2012, 11:06:56 AM
making some nice progress there.
Title: Re: Willyreplica from the start...
Post by: workgoats on October 02, 2012, 11:49:49 AM
Here is the latest...
Title: Re: Willyreplica from the start...
Post by: rjtx667 on October 04, 2012, 08:44:01 AM
looking good!! :great:
Title: Re: Willyreplica from the start...
Post by: phillip637 on October 05, 2012, 09:11:03 AM
looks good man. i like it
Title: Re: Willyreplica from the start...
Post by: workgoats on October 07, 2012, 03:42:56 PM
Here are some pics we took today.  My daughter is driving through a gully behind where I work.

(http://workgoats.com/images/10-07_01.jpg)
(http://workgoats.com/images/10-07_02.jpg)
(http://workgoats.com/images/10-07_03.jpg)
(http://workgoats.com/images/10-07_04.jpg)
Title: Re: Willyreplica from the start...
Post by: workgoats on October 07, 2012, 08:11:17 PM
As you could tell from the previous pics, my daughter and I took it out for a test ride today.

Found and fixed a transmission line leak. I still have a transfer shifter issue but it will wait. If it rains I may be laying in the mud to get it back in 2x.

I'll install a windshield this week and then all I have to do is figure out how to get the fire pit and wood on the trailer with the rig.
Title: Re: Willyreplica from the start...
Post by: crazzywolfie on October 08, 2012, 11:12:31 AM
it looks pretty good. is that going to be its final color?
Title: Re: Willyreplica from the start...
Post by: workgoats on October 08, 2012, 09:31:31 PM
Quote from: crazzywolfie on October 08, 2012, 11:12:31 AM
it looks pretty good. is that going to be its final color?

That is a primer. I was planning a metallic blue but...

I owned my first Jeep in 1965. We painted it '55 Caddy green with a cream colored interior. It had a green canvas top. I dated in that Jeep until I graduated from high school.

Color is still undecided.
Title: Re: Willyreplica from the start...
Post by: crazzywolfie on October 08, 2012, 09:42:58 PM
both colors looks good so i see you having a very hard decision ahead of you.
Title: Re: Willyreplica from the start...
Post by: SixGun on October 09, 2012, 12:46:50 AM
I still like the OD green :PDT_Armataz_01_37:
Title: Re: Willyreplica from the start...
Post by: workgoats on October 09, 2012, 05:48:50 PM
looks like I should paint the bumper....

My wife suggests camo...  but I plan to drive it on the street.

Windshield is to be picked up Friday, installed Saturday and Sunday for building (re-building) windshield wipers.
Title: Re: Willyreplica from the start...
Post by: workgoats on October 13, 2012, 02:19:37 PM
I took the Willyreplica out to Nick's this morning.  We were to put his new window in his RC but after we got the broken one out we discovered that we had the window for the wrong side.  We need a driver's side door window...

Anyway, we did a little playing.  I think the resolution on this video is a little high.  The focus isn't perfect but you can get the idea of how it runs if it doesn't take too long to download.

vimeo.com/51356436 (http://vimeo.com/51356436)
Title: Re: Willyreplica from the start...
Post by: taz_man440 on October 13, 2012, 07:04:12 PM
Lookin great.. what kind of exhaust is on it?  I think it needs stacks.....
Title: Re: Willyreplica from the start...
Post by: workgoats on October 13, 2012, 07:11:06 PM
Quote from: taz_man440 on October 13, 2012, 07:04:12 PM
Lookin great.. what kind of exhaust is on it?  I think it needs stacks.....

It has a used Flowmaster that I took off of Tracy's Cherokee. Only thing I intend to add is a skid plate to protect the lowest part of the transfer. Every thing else is above the bottom of the frame.
Title: Re: Willyreplica from the start...
Post by: SixGun on October 13, 2012, 10:19:31 PM
 Looks and sounds real good.  Are you going to box in the bed?
Title: Re: Willyreplica from the start...
Post by: rjtx667 on October 13, 2012, 10:36:20 PM
looks like you have it about ready to go. I like the video  :great:
Title: Re: Willyreplica from the start...
Post by: workgoats on October 14, 2012, 12:14:33 PM
Quote from: SixGun on October 13, 2012, 10:19:31 PM
Looks and sounds real good.  Are you going to box in the bed?

I plan to close in the back of the tub (cab) and build a short hardwood bed. It will probably be a while. I almost have the heater built. It will require moving the ignition module and the rest of the stuff on the firewall.
Title: Re: Willyreplica from the start...
Post by: REB on November 01, 2012, 12:27:40 AM
Have you ever put the jeep on a scale, with all that steel its got to weight a lot. Cool project though, been thinking of cutting up my cherokee and doing a complete roll bar body. Saw one on the net and a jeep mag, and your blue looks just like that project, really like it too
Title: Re: Willyreplica from the start...
Post by: workgoats on November 01, 2012, 07:11:58 AM
I haven't had a chance to weigh it yet. It "feels" like it is on the light side. But, anything would seem light after driving the red truck. The last time I weighed it (the red truck), it came up at 6,000#. I know the front is a little heavy with the 318/727 but there is not much on the rear. I will close the back of the cab and add a pickup bed but I have ideas to add a minimum of weight. I moved the cab back on the frame for a couple of reasons.  One, to give access to the back of the engine (distributor) and second, to move the weight toward the back as much as possible.
Title: Re: Willyreplica from the start...
Post by: workgoats on November 06, 2012, 08:34:47 AM
I was happy with everything on the rig except the rear suspension.  I came close to ordering stuff for a 4 link but bank account said "NO!"

So, in the mean time I have found an economical add a leaf for the rear.  I think I will be going that way and add some gas shocks. 

I have a heater ready to install.  It is part Cherokee, part J-10, part 2x4 and I used a piece of an old real estate sign.  Problem is that I need to move the ignition module, voltage regulator, and some other stuff off the firewall. 

Now I need to start thinking about closing in the back of the cab.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on November 06, 2012, 09:12:30 AM
How is the accelerator pedal?
Title: Re: Willyreplica from the start...
Post by: workgoats on November 06, 2012, 02:36:53 PM
Quote from: rjtx667 on November 06, 2012, 09:12:30 AM
How is the accelerator pedal?

I've only started it twice since I came home but it is still good.  I found another pedal last night so I might change out the cable or the little keeper.  On the other hand, there is nothing wrong with zip ties...
Title: Re: Willyreplica from the start...
Post by: SixGun on November 06, 2012, 07:39:43 PM
 :laughing4:

Ryan I still think you should have let me pull it through the mudhole.  :laughing7:
Title: Re: Willyreplica from the start...
Post by: rjtx667 on November 07, 2012, 10:41:30 AM
I was not going in there... I had enough issues driving a carb as it was... Me and Carb's don't seem to get along, guess thats why all mine are MPFI  :laughing7:

As I recall you decided to not go in the mud hole either. Too bad, would have been funny to see water at the top of your cab.
Title: Re: Willyreplica from the start...
Post by: workgoats on November 07, 2012, 12:14:36 PM
I think I should be glad I was not with you for this conversation.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on November 07, 2012, 02:11:26 PM
You recall the "mud hole" that he wanted to drive through when you were driving? We went back there and tested it out with some rocks... You would need a very large snorkel.... and not just for the engine

:sign0135:

that was pretty much both of our instant response to the idea after that.
Title: Re: Willyreplica from the start...
Post by: SixGun on November 07, 2012, 10:38:07 PM
Yeah but that was the first hole.  Remember the big bowl with water just off the fenceline where the gas pedal went kaput.  I tried talking Yolanda into going through that one but she was worried that the Willy's might not have enough gas to pull me out if it went south.   :brushteeth:  BTW I'm still cleaning mud.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on November 08, 2012, 11:08:56 AM
Quote from: SixGun on November 07, 2012, 10:38:07 PM
Yeah but that was the first hole.  Remember the big bowl with water just off the fenceline where the gas pedal went kaput.  I tried talking Yolanda into going through that one but she was worried that the Willy's might not have enough gas to pull me out if it went south.   :brushteeth:  BTW I'm still cleaning mud.


At least its not red clay... sounds like people are still working on that from RJ 3 years ago
Title: Re: Willyreplica from the start...
Post by: SixGun on November 09, 2012, 02:09:16 AM
Ron, don't know if it's an option for you but Ryan's heater box is available.  Bolt pattern was completely different from the 76 RC.  It's still in one piece.   Ended up at Dave's for the 3rd time and got a match.  3rd time was a charm - whaddaya know.
Title: Re: Willyreplica from the start...
Post by: workgoats on November 09, 2012, 05:55:51 AM
I built one using the Jeep box, cut down and without the a/c coil. It is almost too big. I will not get to work on it much for a while. There is too much going on.
Title: Re: Willyreplica from the start...
Post by: workgoats on November 16, 2012, 06:52:01 AM
Here are a couple of short videos from our trip to Hidden Falls.  This was the rig's first test.  I didn't trust the tires to survive being aired down and there is still some suspension work to be done.  As well as finishing the back end of the truck.

vimeo.com/53674704 (http://vimeo.com/53674704)
vimeo.com/53674705 (http://vimeo.com/53674705)
Title: Re: Willyreplica from the start...
Post by: workgoats on November 16, 2012, 04:36:24 PM
I am currently doing some wiring remodeling. I'm simplifying the fuse panel. I have rebuilt an older Ramcharger fuse box with wires and fuses to match what I actually have on the truck. I also have to move the ignition module and voltage regulator to make room for the heater. While I'm at it, I plan to remove, remodel and re-install the wiper system to get better coverage on the windshield.

Add a leaf system for the rear is ordered. We will see if this makes it more trail worthy. It should lift the back end by about 2.5 inches.

Also in planning mode for closing in the back of the cab and designing a pickup bed to go on the back, as well as raising the rear bumper for a better departure angle.
Title: Re: Willyreplica from the start...
Post by: workgoats on November 17, 2012, 05:31:05 PM
Well, I installed the heater I built.  It almost fits.  I will have to move the battery forward about 2" to clear the blower motor.  That's not too much of a problem.  I had to remove the voltage regulator, ignition module, ballast resistor and a junction block to install the heater but they were all ok to put back after installation.

There is a space conflict with the transfer shifter, but since it didn't work very well anyway, I guess I will rebuild it AGAIN.  That means I will have to remove the 150# skid plate I put in before going to Hidden Falls. 

At least it kept me from putting any scratches or cracks in the transfer.

Oh yeah, the fuse block was in the way of the heater so I rebuilt a RC fuse block and rewired it to handle only what I expect to have on the Willyreplica.  It is a much better application and I now know what all the little fuses are really for.
Title: Re: Willyreplica from the start...
Post by: SixGun on November 17, 2012, 07:17:23 PM
Come on Ron, give us some pics.   :wave:
Title: Re: Willyreplica from the start...
Post by: workgoats on November 17, 2012, 10:52:34 PM
Quote from: SixGun on November 17, 2012, 07:17:23 PM
Come on Ron, give us some pics.   :wave:

I can't find my camera.  I guess I can take some with the phone tomorrow.
Title: Re: Willyreplica from the start...
Post by: workgoats on November 18, 2012, 08:38:28 PM
Still can't find my camera.  Don't be surprised if these come up upside down or something. 

First pic is the bumper.  Since a couple of guys claimed it was too low, I have raised it 5".  I did some work on it after the pic but it is still not finished yet.

Second picture is the new fuse block.  It is from some undetermined year model of Dodge P/U or RC.  I have rewired it to include what is on the vehicle now and what I intend to add, with one spare for something new...

Third and fourth pics are of the heater.  They are hard to see.  One is from the passenger door.  There is a conflict with the transfer shifter just out of the pic to the left.  I need to re-do the shifter anyway so this will be resolved.  By the way, you can see a zip tie holding the cable to the gas pedal.  That was not part of my build.  Seems Ryan and Richard did this while I was in camp.

The other pic is of the firewall.  All the ignition and voltage stuff has been reinstalled.  The blower motor can be seen and the hose bibs stick out through all the wiring to the right.  I haven't hooked them up yet because I don't have a valve to regulate the water flow yet.  When I get everything working as it needs to be I plan to re-do the wiring on the firewall to clean it up.

The thing may be worn out by the time I get it done. :steeringwheel: (http://:steeringwheel:)
Title: Re: Willyreplica from the start...
Post by: SixGun on November 19, 2012, 12:13:13 AM
Trying to remember, was the bumper below the frame previously?  Looks like you've gotten quite a bit done.   :great:
Title: Re: Willyreplica from the start...
Post by: workgoats on November 19, 2012, 06:24:47 AM
Quote from: SixGun on November 19, 2012, 12:13:13 AM
Trying to remember, was the bumper below the frame previously?  Looks like you've gotten quite a bit done.   :great:

Top of bumper was same elevation as bottom now. I also moved it 2 inches forward. I have fabricated two 2"x2" vertical bump stops from top of bumper to bottom of the bumper frame that you can see below the bumper.
Title: Re: Willyreplica from the start...
Post by: workgoats on November 22, 2012, 08:21:50 AM
Those of us that were at Hidden Falls last are aware that it needed some help in the rear.  I have raised the bumper 5" and will try to finish welding and reset it today.  I bought a pair of add a leaf springs from a Jeep on line company, Iron Rock Offroad.

The lift was to be 2.5 to 3 inches, depending on spring condition and weight.  Since I don't have any weight at the back (yet) it lifted the back by 3 3/4".  I think that is more than I need but by the time I get the back of the tub completed, add a bed, spare, tools and extraction stuff, spare and whatever, I hope it will lower itself an inch or so.

Cost of the kit was under $80, including shipping.  The U-bolts were like new so I reused them.  You Texas guys should remember that and not follow me too closely...

(http://workgoats.com/images/before_spring.jpg)


Here was the measurement to the top of the receiver hitch before adding the springs.  I didn't bother to take one showing the additional 3 3/4".

The spring kit included 2 full length springs, center bolt and nut (extra long to make it easy to install) and clamps to hold the springs in place.  All went very well.

(http://workgoats.com/images/spring.jpg)

In the meantime...

(http://workgoats.com/images/boat.jpg)

No I didn't get to use the boat.  I just moved it around while we used its home for the painters to finish cabinets for our new buildings.
Title: Re: Willyreplica from the start...
Post by: SixGun on November 23, 2012, 01:04:18 AM
So lifting the bumper 5" and 3" lift springs for an 8" raise on the ass end round abouts?  Sounds like the rock scraping days are over.   :13:
Title: Re: Willyreplica from the start...
Post by: workgoats on November 23, 2012, 05:49:23 AM
Quote from: SixGun on November 23, 2012, 01:04:18 AM
So lifting the bumper 5" and 3" lift springs for an 8" raise on the ass end round abouts?  Sounds like the rock scraping days are over.   :13:

Yep. It looks like I will have to get a 12 inch drop hitch to pull a trailer.  :laughing7: (http://:laughing7:)
Title: Re: Willyreplica from the start...
Post by: SixGun on November 23, 2012, 09:57:04 AM
You ever notice that fixing one problem always seems to create another one.   :icon_scratch:
Title: Re: Willyreplica from the start...
Post by: workgoats on December 09, 2012, 01:07:54 AM
Okay, I got a new camera...

These first two pics are of the modified rear bumper, raised 5 inches.  Bump stops were added to help reinforce it and the receiver for the hitch is attached to an angle crossing from side to side under the gas tank.

Departure angle is greatly improved.

(http://workgoats.com/images/12-09_01a.jpg)

(http://workgoats.com/images/12-09_02a.jpg)

I installed an add-a-leaf kit from Iron Rock Off Road.  They are a Jeep supplier.

The lift was more than I actually  wanted but it should come back down a little as I finish the back of the vehicle.

(http://workgoats.com/images/12-09_06a.jpg)

The added height caused problems with the u-joint at the transfer case.  It did not handle the added angle.  I ground on the yoke for a while until it didn't hit the caps anymore but ordered a slip yoke eliminator from Iron Rock.

Here are pics of both ends of the rear driveshaft and the parts I received for the slip yoke removal.

(http://workgoats.com/images/12-09_03a.jpg)

(http://workgoats.com/images/12-09_04a.jpg)

(http://workgoats.com/images/12-09_05a.jpg)

Driveshaft removed:
(http://workgoats.com/images/12-09_07a.jpg)

Rear housing removed:

(http://workgoats.com/images/12-09_08a.jpg)

Just a little over an inch of the shaft was removed.  The center of the shaft is not hardened.  I drilled it out, tapped it and installed the new yoke with a 3/8 in bolt to hold it on.  The adapter is milled aluminum and holds the new oil seal.

(http://workgoats.com/images/12-09_09a.jpg)

Next steps will be turning the differential toward the transfer to eliminate vibration due to the addition of a double cardan joint at the transfer.  I get this from a front driveshaft that Richard is holding (whenever we can get together).

In a standard XJ, the rear driveshaft would be replaced with a stock front driveshaft, making both front and rear identical.  This won't happen to me since I went from the 904 tranny to the 727 and had to shorten the driveshaft.

I will have pics soon of the re-alignment of the rear axle but it will require new u-bolts and I will be beefing up the spring top plates too.  The wedges/shims required to turn the axle also require some modifications to the bolt holding the springs together. 
Title: Re: Willyreplica from the start...
Post by: SixGun on December 09, 2012, 09:21:34 PM
I really like the way you braced that rear bumper.  Looks tough!   :great:
Title: Re: Willyreplica from the start...
Post by: workgoats on December 12, 2012, 09:34:25 PM
The rear axle is now bolted back to the springs.  I had to extend the bottom of the bolt through the springs by adding a spacer.  The wedge to correct the angle of the pinon shaft had a hole all the way through it. 

I was fed up with the spring plate and we fabricated new ones, using 1/2" plate.  I like it.

(http://workgoats.com/images/12-12_01.jpg)

And here is a look at the back of the wedge.

(http://workgoats.com/images/12-12_02.jpg)
Title: Re: Willyreplica from the start...
Post by: workgoats on December 27, 2012, 07:19:41 PM
As I got older, I found it harder to turn around in the seat and back safely.  I also hate getting out of the truck 5 or 6 times to get a trailer hooked up to the hitch.  So, I'm back on a rear view/backup camera system for this vehicle.

In the past I have used both hard wired and wireless cameras.  In the red truck I have a 7" monitor with one wireless input and one AV input.  I put a security camera in the bumper.

(http://workgoats.com/images/IMG_0102a.jpg)

This was a good application except for the fact that it does not have sufficient field of vision to see the top of the trailer ball.  You can back up close to the trailer but you cannot tell when you are in the right location.

To cure this I took a wireless camera that I bought some time back (with the monitor) and installed it up under the spare.  It looks down directly on the hitch and makes hookup a breeze.

(http://workgoats.com/images/IMG_0104a.jpg)

Then at Shiloh Ridge I came fairly close to running over a guy on a 4-wheeler sitting at the top of a hill.  I guess he didn't think there was a way in the world for such an ugly truck to make it to the top of the hill.  I couldn't see him until I broke over the top of the hill.  To solve that problem I installed another wireless camera in the grille.  It was pointed downward enough to see right in front of the bumper.

(http://workgoats.com/images/IMG_0105a.jpg)

I put the two wireless cameras on an A/B switch.  The security camera in the bumper is a 9 volt camera and I used a solid state voltage regulator but the power supply that came with the camera put out over 14 volts so I think the camera would work fine on battery voltage.

As of today, neither of the wireless cameras work.

I have purchased a new security camera for the Willyreplica.  It is identical to the one in the bumper shown above.  It came from Harbor Freight and they are often on sale for $30 or so.  Here is the complete package.

(http://workgoats.com/images/IMG_0100a.jpg)

With a little help from a salesperson at Best Buy, I found a 7" monitor designed for a backup camera on-line.  This monitor has two AV inputs and is powered by a switch or by a lead to the backup light so that it will come on when the vehicle is put in reverse.

(http://workgoats.com/images/IMG_0101a.jpg)

This monitor came with an adapter that would let you install it directly in the dash.  It also has a stand.  Since I don't have a space big enough in my little dash, I will use the stand.

I plan to mount the camera above the rear bumper and place it on a hinged mount so that I can tilt it downward enough to see the trailer ball or high enough to look backwards both on the trail and on the highway.  The jury is still out on what I will use for the linear actuator to move it up and down.
Title: Re: Willyreplica from the start...
Post by: workgoats on December 29, 2012, 07:09:06 AM
Working on the rear view camera...

The first thing I have done is remove the base from the camera.

(http://workgoats.com/images/IMG_0111.jpg)

Then I modified a gate hinge and built a cradle for the camera.  I used part of the same plastic cutting board that I used to make the front spring spacers.

(http://workgoats.com/images/IMG_0112.jpg)

I clamped it to the top of the bumper.  (This is NOT a permanent mounting.)

(http://workgoats.com/images/IMG_0114.jpg)

And this is the night vision view out the door of my garage, Christmas lights and all.  There was some light out there, but the camera was in night vision mode.

(http://workgoats.com/images/IMG_0119.jpg)

Then, this would most likely be the amount of tilt that I would want.

(http://workgoats.com/images/IMG_0116.jpg)

This is the night vision view of the trailer ball from the tilted camera.  There was very little ambient light there so this would be the view backing to a trailer with no backup lights.  We are looking at the concrete drive, garage floor and a concrete block sitting just out on the edge of the drive.

(http://workgoats.com/images/IMG_0118.jpg)

There may be some sun today and if I can I will move it outside and look at the views again without the night vision.

Next problem is the linear actuator that would be needed to move and control the tilt of the camera.  I'm working on that.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on December 31, 2012, 08:05:33 AM
that is a sweet setup there!!!  :great:
Title: Re: Willyreplica from the start...
Post by: workgoats on December 31, 2012, 09:14:59 PM
I think I have found the answer for the linear actuator.  I've found a unit that is 9 1/4" inches long and less than 1 1/4" in diameter.  It has 2 inches of movement with limit switches at both ends.  I think I will mount it horizontal behind the bumper and translate the action to vertical with a small bell crank.  That will let me alter the length to match what is needed since the limit switches are not adjustable.

It's a little pricey but it should cut out about 3 or 4 of the methods that just don't quite work.
Title: Re: Willyreplica from the start...
Post by: workgoats on January 14, 2013, 08:06:28 PM
I have been working on the rear view/backup camera on the project.  I have built a device to tilt the camera so that I can see the camera ball when hitching up a trailer.  On the previous truck I mounted a second camera behind the spare tire.  I found that it was okay in the daylight but at night there was insufficient light to see the trailer ball.

I have rigged this one up to tilt toward the ball.  This camera is a night vision security camera, bought on sale from Harbor Freight for less than $40.  The monitor was bought on-line from a Best Buy site for about $40.00.  The linear actuator was purchased on line and it cost about $105.  Who knows what the switch in the dash will require.  It will have to be a double pole, double throw rocker arm switch to match the others.

Here is the mechanism to tilt the camera.  I had to modify the backing plate some to get it behind my bumper and since it was so hard to get it installed I will not be pulling it out to paint it.  (At least not in the near future.)

(http://workgoats.com/images/01-13-13_01a.jpg)

Here is a short video of the camera tilting and the view on the monitor when you tilt the camera.  The truck is in the garage and it is at night.  It was cold enough it should have been showing...  The garage door was not open long.

vimeo.com/57419018 (http://vimeo.com/57419018)
Title: Re: Willyreplica from the start...
Post by: rjtx667 on January 15, 2013, 08:43:10 AM
Thats a pretty sweet setup right there!!! :13:

Title: Re: Willyreplica from the start...
Post by: workgoats on February 02, 2013, 07:13:01 PM
I bought some metal today to begin closing in the back of the cab and for building a frame for a top.  There is a problem though because I also brought my new 82 RC from Nick's house home today too.   I borrowed a driver side window glass from AJ today and will need to replace it sooner or later.

The Magnum is running but there's a long way to go to get the program worked out.  I will be starting on it soon.  If I can learn how to handle this, I'll put the 360 TBI stuff on the 318 in the Willyreplica and install the other MegaSquirt computer that I have.

I'm still wiring the Willyreplica to run the new 12K winch in the receiver hitch at the front and the back. 
Title: Re: Willyreplica from the start...
Post by: workgoats on February 02, 2013, 07:23:38 PM
Okay, I have a battery running the Willyreplica and a battery in the back to run the winch.  I plan to keep the batteries separate but I need to keep the winch battery charged.

I have a battery isolater somewhere but, if I install a wire from the positive wiring on the truck, through a relay that is closed when the ignition is in the run position, properly fused, would that serve as a isolater for charging when the truck is running and prevent the winch battery from running down the truck battery?  Would it need a diode to prevent problems?

I also am wondering if I put a permanent set of jumper cables between the batteries, switched with a couple of ferd type starter solenoids powered by a dash switch, could  I safely tie the two batteries together to assist in winching or as a jumper battery if the truck battery was run down?
Title: Re: Willyreplica from the start...
Post by: SixGun on February 02, 2013, 11:45:36 PM
So are you talking about enclosing the cab only or the bed too.  I really think that the bed will give it a whole new look.  Then a machinegun mount in the bed with a 50 cal.  Hooah.... :evil6:
Title: Re: Willyreplica from the start...
Post by: workgoats on February 03, 2013, 05:19:20 AM
I plan to close the cab and then have basically a short flat bed. But, there will be bed sides made from the "Brazilian Walnut" scraps from our new office. It is Ipe wood. It is just about the hardest wood in the world.

I would have the only Willyreplica in the world with this wood on it.

It could turn into a metal bed though. Just depends on time, amount of materials, appearance and whatever.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on February 03, 2013, 05:12:05 PM
I have a spare driver (and passenger, and rear quarter side, and hatch) window if you need one.  :laughing7:
Title: Re: Willyreplica from the start...
Post by: workgoats on February 03, 2013, 05:23:29 PM
Quote from: rjtx667 on February 03, 2013, 05:12:05 PM
I have a spare driver (and passenger, and rear quarter side, and hatch) window if you need one.  :laughing7:

I borrowed a driver side window glass from AJ. He's  a local guy that you haven't met yet. It came from a pop top RC but the glass will be the same. We might have to swap the metal runner on the bottom but that is doable. It should be the same unless your glass came from a truck with electric windows.

So, yes I need a driver side glass.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on February 03, 2013, 09:11:43 PM
It did have electric windows, but then again I got the spare electric motors too if you want to get all fancy  :laughing7:

They are sitting in my warehouse office along with all my other spare parts.

This LASIK messed with me a bit more than I thought, I am freaking out about messing up the flap and all that, but I should be back on game here in a week or so and hopefully get some more stuff worked on.

I sold the 91 buick, so I am back down the 4 vehicles... figure thats a good start.

Just let me know if you want the window(s) and/or the electric motors as well. I think I still have the whole dash wire harness (and dash even)
Title: Re: Willyreplica from the start...
Post by: workgoats on February 10, 2013, 07:29:10 AM
I actually have been working on the Willyreplica some.  Chickenlittle gave me an air tank from some truck.  I modified it a little, using switches and regulator from a home air compressor but using the tank's check valve.  This is the first fit in the truck, between the soon to be finished cab and the gas tank on top of the frame.

(http://workgoats.com/images/photo_(22).jpg)

I have lowered the mounting brackets and relocated the regulator so it will have a lower profile.  I put a little paint on it but the spray nozzle died about half through and it won't be seen anyway...

(http://workgoats.com/images/photo_(23).jpg)

I have also started building the roof structure, following the slope of the roll bar.  The fitment at the corner was a real pain and the welding leaves some to be desired but it isn't structural.  (In the end it won't be seen anyway.)

I don't really understand it though, usually the welds that can't be seen are great and the ones in front of my everyday vision are terrible. 

(http://workgoats.com/images/photo_(19).jpg)

(http://workgoats.com/images/photo_(20).jpg)

(http://workgoats.com/images/photo_(21).jpg)
Title: Re: Willyreplica from the start...
Post by: workgoats on February 10, 2013, 08:59:13 AM
The c-clamps and the tubing across the top are for alignment.  They are not permanent.  :icon_scratch: (http://:icon_scratch:)
Title: Re: Willyreplica from the start...
Post by: SixGun on February 10, 2013, 11:20:34 AM
 :icon_salut:  Could always hang a flag off the C-clamp.
Title: Re: Willyreplica from the start...
Post by: workgoats on February 10, 2013, 01:04:23 PM
Quote from: SixGun on February 10, 2013, 11:20:34 AM
:icon_salut:  Could always hang a flag off the C-clamp.
Aggie flags come with a flag pole.
Title: Re: Willyreplica from the start...
Post by: workgoats on February 13, 2013, 08:37:11 PM
Here's a pic of the location for my on-board air tank and the battery for the winch.  The cab is to the right, gas tank to the left.

(http://workgoats.com/images/below.jpg)

And here is a look at what I plan to do to the floor of the bed.  The dark wood is Ipe wood from South America and the light wood is unknown.  It came as a support for some device that was delivered to our shop.  I plan to make a door above the air tank and battery compartment and hinge it from the front (back of cab).  There should be room for a jack, some u-joints and other stuff that we tend to break on the trail.

(http://workgoats.com/images/deck.jpg)
Title: Re: Willyreplica from the start...
Post by: SixGun on February 14, 2013, 12:49:37 AM
Looks like a nice little trunk space.  We're not gonna recognize it by the time RJ comes around.
Title: Re: Willyreplica from the start...
Post by: workgoats on February 21, 2013, 10:33:20 PM
I have steadily been working on this thing. 

I have finished the on board air, except for a line to a quick connect on the outside. 

I have installed the battery for the winch and wired it to plugs on both bumpers.  That will let me use the winch and the jumper cables at both ends. 

I am almost through with the framing for the cab.  It's not exactly what I had originally planned but it will do.  I haven't designed the rear window yet and I will have to go pick up some more material but I "have an idea".

I have installed a battery isolater on the firewall  and all is complete except for drilling a hole in the floor and attaching it to the second battery.

I am off tomorrow because I have to work this weekend.  It is not supposed to rain so maybe I can get it outside and take some pics.  That would let me have a chance to clean out the garage a little too.  No telling how many tools I can find if I could find the floor.

Ernest and I want to do a test drive early in April.  Anyone else gonna be ready to make a run to Hidden Falls or General Sam's?  (I think Ernest will be driving a ferd...)

By the way, I bought a wireless remote for the new 12,000 winch and have almost 140 feet of new plasma rope to put on it too.  The plasma rope will cut, but the breaking strength is about 2 times that of steel of the same diameter.  I'll have to carry some carpet to protect it over ledges and stuff.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on February 22, 2013, 11:49:18 AM
http://ramcharger.net/index.php/topic,118.0.html

I am game... started a thread for us in a new section just so we can try to keep track.  :laughing7:
Title: Re: Willyreplica from the start...
Post by: workgoats on February 22, 2013, 07:45:41 PM
I have started building the cab.  I had originally planned on using the same radius at the back of the cab as the cowling and fender radius'.  However, I just simply don't have the time now.

Here is the start.  First picture is hard to see what I have done due to the white on white of the pic.

(http://workgoats.com/images/02-21-13_01a.jpg)

(http://workgoats.com/images/02-21-13_02a.jpg)

I have installed a battery isolater to keep the battery for the winch charged.

(http://workgoats.com/images/02-21-13_08a.jpg)

Here is the battery for the winch and the tank for the on-board air.  Both are located in a compartment behind the cab and in front of the gas tank.  I will have a door in the bed of the "pickup bed" to allow access.  The air line will extend into the compartment over the gas tank where I plan to store the straps and stuff.

(http://workgoats.com/images/02-21-13_03a.jpg)

(http://workgoats.com/images/02-21-13_04a.jpg)

(http://workgoats.com/images/02-21-13_05a.jpg)

Here is where I started with the winch today.  It had steel rope and I used an old roller fairlead because I didn't want to scratch up the new one before I installed the plasma rope.

(http://workgoats.com/images/02-21-13_06a.jpg)

The line was attached with a set screw holding it in a hole cast in the drum.

(http://workgoats.com/images/02-21-13_09a.jpg)

Here is what it looked like after installing the plasma rope and the new fairlead.

(http://workgoats.com/images/02-21-13_10a.jpg)

I have these plugs on both bumpers, attached to the winch battery.  I have a set of jumper cables that plug into this too.  If the battery is down on the engine, I can jump it from the plug on the front bumper.

(http://workgoats.com/images/02-21-13_07a.jpg)

After I backed it back into the garage, I took a pic of the winch on the front bumper.  I suspect that on the trail I will keep the winch in the back bumper as it appears to be safer.

(http://workgoats.com/images/02-21-13_11a.jpg)

It is amazing how much lighter the winch is with the plasma rope as opposed to the wire rope.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on February 22, 2013, 10:14:03 PM
makes me want a winch... and the receiver setup you have.  :evil6:
Title: Re: Willyreplica from the start...
Post by: SixGun on February 22, 2013, 11:43:26 PM
Good time to trade services.  Ron can make you some receivers front and rear and you can set up his TBI setup with the computer.  Win Win   :035:
Title: Re: Willyreplica from the start...
Post by: rjtx667 on February 23, 2013, 12:18:05 AM
Quote from: SixGun on February 22, 2013, 11:43:26 PM
Good time to trade services.  Ron can make you some receivers front and rear and you can set up his TBI setup with the computer.  Win Win   :035:

and here I just planned on getting his while he was distracted  :dance:

I want to try fabbing my own, as long as people don't laugh at me too much  :laughing7:
Title: Re: Willyreplica from the start...
Post by: workgoats on February 25, 2013, 09:33:21 PM
Here is the update on the camera situation:

The rear camera still tilts and I pulled the camera from the red truck and put it in the grille.  It's a little obvious but what the heck.

(http://workgoats.com/images/02-25-13_01a.jpg)

I also decided to put the monitor in the dash.  I don't have a very big dash but this will do.

(http://workgoats.com/images/02-25-13_02a.jpg)
Title: Re: Willyreplica from the start...
Post by: ernestgonzales78@gmail.com on February 27, 2013, 08:58:07 PM
Guys this man needs a hobby. He has to much time and energy and money. I'm waiting on him to install a butt warming in this thing. lol
Title: Re: Willyreplica from the start...
Post by: workgoats on February 27, 2013, 09:45:26 PM
Quote from: chicken-little78 on February 27, 2013, 08:58:07 PM
Guys this man needs a hobby. He has to much time and energy and money. I'm waiting on him to install a butt warming in this thing. lol

The fake leather, electric seats are waiting in the barn at work but I really hadn't thought about a butt warmer. :icon_scratch: (http://:icon_scratch:)
Title: Re: Willyreplica from the start...
Post by: SixGun on February 28, 2013, 12:22:54 AM
Quote from: chicken-little78 on February 27, 2013, 08:58:07 PM
Guys this man needs a hobby. He has to much time and energy and money. I'm waiting on him to install a butt warming in this thing. lol

So are you planning on being a passenger again??   :laughing7:
Title: Re: Willyreplica from the start...
Post by: rjtx667 on February 28, 2013, 09:48:15 AM
Quote from: workgoats on February 27, 2013, 09:45:26 PM
The fake leather, electric seats are waiting in the barn at work but I really hadn't thought about a butt warmer. :icon_scratch: (http://:icon_scratch:)

I would suggest to focus on a butt cooler before a butt warmer... it gets hot in August  :laughing7:

Its why my 93 will have all windows and A/C fully charged for RJ
Title: Re: Willyreplica from the start...
Post by: ernestgonzales78@gmail.com on March 01, 2013, 09:57:31 PM
Richard I haven't decided yet. I'm working on getting the mistress ready. I hope it is ready and can handle the steep rocks. We'll see  :dance: :dance:
Title: Re: Willyreplica from the start...
Post by: workgoats on March 02, 2013, 05:06:01 PM
I'm finally getting to the bed on this thing.  Here's a little evidence of progress:

(http://workgoats.com/images/03-02-13_01a.jpg)

I started by determining how high and building a corner at the back to start from.  I'm using culled Ipe wood boards from our new office.  This should be the only Willyreplica in North America with an Ipe wood bed.

I have also started on the back of the cab.  I will need to borrow a truck or trailer and go get some more FRP to go on the back of the cab, behind the wood of the bed, before I can actually install any wood.

(http://workgoats.com/images/03-02-13_03a.jpg)

Here is an idea of what it will look like from the side.  I suspect a vertical batt will be installed in front of the roll bar to keep the wood in line.

(http://workgoats.com/images/03-02-13_04a.jpg)

And, here is my concept of inside the bed.  The boards on the floor will be cut and screwed to metal door frames, making two doors that will open to the two compartments below the floor.
(http://workgoats.com/images/03-02-13_05a.jpg)
Title: Re: Willyreplica from the start...
Post by: ernestgonzales78@gmail.com on March 02, 2013, 07:40:37 PM
Thats pretty freaking sweet!! It's turning out good.
Title: Re: Willyreplica from the start...
Post by: workgoats on March 02, 2013, 07:53:40 PM
When it's done I'm gonna have to move the tail lights.  I'm gonna try to go with a one light system and use the LED tail lights off the red truck.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on March 02, 2013, 08:28:13 PM
I agree, very nice looking.

When are you going to start giving lessons? Between you and Jim ya'll make the rest of us look like the rednecks we are  :laughing7: :tard:
Title: Re: Willyreplica from the start...
Post by: SixGun on March 02, 2013, 10:33:22 PM
Tell me about it....   :You_Rock_Emoticon:
Title: Re: Willyreplica from the start...
Post by: workgoats on March 03, 2013, 07:58:51 PM
So, today I framed in for the rear window.

(http://workgoats.com/images/03-03-13_01a.jpg)

Then I put the FRP on the back of the cab.

(http://workgoats.com/images/03-03-13_02a.jpg)

Then I actually started installing the wood bed.  I plan to remove it, a board at a time if necessary to paint the rig.  The wood will need to be oiled on the back side too.  It has been oiled on one side already.  This is as far as I got.  I ran out of time, energy, and worst of all light.  I need to upgrade my lighting somewhat or spend more work in the daylight.

(http://workgoats.com/images/03-03-13_03a.jpg)

Here is a look from a little farther back.  I would have liked to pulled it outside and clean the garage and take some pics but I didn't want to take the time to reinstall a seat.

Those flat fenders make really neat places to stack stuff.  And, did you notice that I got some new shoes.  I'm working hard on being ready to go somewhere.

(http://workgoats.com/images/03-03-13_04a.jpg)
Title: Re: Willyreplica from the start...
Post by: rjtx667 on March 03, 2013, 11:30:13 PM
those tires look just a wee bit nicer than what you had.

Its going to look sharp with that wood bed... I dig it, I really dig it  :laughing7:  :13:
Title: Re: Willyreplica from the start...
Post by: SixGun on March 04, 2013, 12:45:27 AM
So what type and size are the tires?  They look good.   :thumbsup:
Title: Re: Willyreplica from the start...
Post by: workgoats on March 04, 2013, 06:11:08 AM
Tires are 32x11.5x15 Sport King. I guess they are all terrains. I put the 33s and wheels from the red truck on the RC from Nick and the tires from Nick's were mounted on the Willyreplica. Sad part is that it hasn't been out of the garage since the tires were mounted. 

I hope to tow it to work toward the end of the week so I can drive it around a little. I would like to see how bad they are going to rub.

I suspect they are wide enough that I may have to extend the front fenders to get a title. Guys have told me that tires cannot extend out that far to satisfy the DOT people.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on March 04, 2013, 07:52:31 AM
Quote from: workgoats on March 04, 2013, 06:11:08 AM
Tires are 32x11.5x15 Sport King. I guess they are all terrains. I put the 33s and wheels from the red truck on the RC from Nick and the tires from Nick's were mounted on the Willyreplica. Sad part is that it hasn't been out of the garage since the tires were mounted. 

I hope to tow it to work toward the end of the week so I can drive it around a little. I would like to see how bad they are going to rub.

I suspect they are wide enough that I may have to extend the front fenders to get a title. Guys have told me that tires cannot extend out that far to satisfy the DOT people.


sounds easier to borrow a smaller set of tires for the title inspection, your daughter has some 31's on the same bolt pattern I believe?  :icon_scratch:

Will be cool once its titled and on the street.

Are you driving the new RC around yet? You play with the computer at all?
Title: Re: Willyreplica from the start...
Post by: workgoats on March 04, 2013, 03:51:55 PM
Quote from: rjtx667 on March 04, 2013, 07:52:31 AM

sounds easier to borrow a smaller set of tires for the title inspection, your daughter has some 31's on the same bolt pattern I believe?  :icon_scratch:

Will be cool once its titled and on the street.

Are you driving the new RC around yet? You play with the computer at all?

I need to extend the front fenders anyway because if I don't I will be getting mud in the face all the time. 

I have not yet done anything with the RC other than buying and downloading the tuning program and the viewer.  I'm not sure my computer will work with the usb serial adapter.
Title: Re: Willyreplica from the start...
Post by: SixGun on March 04, 2013, 03:56:27 PM
 
Quote from: workgoats on March 04, 2013, 03:51:55 PM
I need to extend the front fenders anyway because if I don't I will be getting mud in the face all the time. 

I think you should test it first and let us get some pictures
Title: Re: Willyreplica from the start...
Post by: workgoats on March 04, 2013, 04:23:15 PM
Quote from: SixGun on March 04, 2013, 03:56:27 PM

I think you should test it first and let us get some pictures

thanks :icon_scratch: (http://:icon_scratch:)
Title: Re: Willyreplica from the start...
Post by: phillip637 on March 04, 2013, 05:15:32 PM
lookin good  :thumbsup:
Title: Re: Willyreplica from the start...
Post by: workgoats on March 08, 2013, 10:38:28 PM
The bed is nearing completion.  I still have to put the floor together.  It will be a trap door.  There are the two compartments below it with the tools, battery and air tank.

The dark wood is Ipe wood and the light colored is something that arrived as packing protection for something delivered to our warehouse.  I will be poly-urethaning the light colored wood but the Ipe wood will be oiled.  Then I plan on painting the steel and fiberglass around the area before doing a final install on the wood.
(http://workgoats.com/images/03-08-13_01a.jpg)
Title: Re: Willyreplica from the start...
Post by: SixGun on March 09, 2013, 02:05:41 PM
Damn Ron, you should've worked for Detroit.   :icon_salut:

That wood looks really good.  I noticed the lights went to over and under.  I like the trap door idea.  Are you going to be able to secure it with a lock of some sort?
Title: Re: Willyreplica from the start...
Post by: workgoats on March 09, 2013, 02:29:13 PM
Quote from: SixGun on March 09, 2013, 02:05:41 PM
Damn Ron, you should've worked for Detroit.   :icon_salut:

That wood looks really good.  I noticed the lights went to over and under.  I like the trap door idea.  Are you going to be able to secure it with a lock of some sort?

I hate tail lights. Spent two nights messing with them. The Old mounts for the lights will have to stay because they help support the fenders. One set is LED and the other is old school.

There will just be one door and I will make it key lockable but probably not before April.

Tomorrow I plan to dis-assemble all the wood and paint the metal around it. I hope I can figure out how to put it back together.
Title: Re: Willyreplica from the start...
Post by: SixGun on March 09, 2013, 02:53:24 PM
Number them in an inconspicous location.
Title: Re: Willyreplica from the start...
Post by: workgoats on March 09, 2013, 07:17:34 PM
Quote from: SixGun on March 09, 2013, 02:53:24 PM
Number them in an inconspicous location.

Probably won't get that far tomorrow.  Spent part of today at a play day, watching a grand-daughter ride barrels.  I still have one piece to do, a top rail with the round roll bar running through it at a 50 degree angle.
Title: Re: Willyreplica from the start...
Post by: workgoats on March 12, 2013, 10:43:30 PM
I finally got a chance to drive it out of the garage tonight.  I discovered that at least part of my garage still has a concrete floor.

Here is the view of the new bed as I pulled it out.

(http://workgoats.com/images/03-12-13_01a.jpg)

And here is the front view.  Changes since it was last outside include the new tires, 32x11.50x15 ATs that I removed from the RC in the driveway.  I put my 33s from the no longer red truck on the RC.  Of course, the bed and the cab are new too.

(http://workgoats.com/images/03-12-13_02a.jpg)

Here, parked by the RC, it looks a lot bigger than it really is.  The tires on the RC are 33s and the ones on the Willyreplica are 32s.

(http://workgoats.com/images/03-12-13_03a.jpg)

From the rear it is a in a little better perspective.  The cab is very small.  The seats are close together and there is very little room between the seat and the door.  It is high but I did the best I could to keep the weight low.  When it had a 904 tranny instead of the 727 that is in it now, there wasn't any hump at all.  Now it has about a 3" hump.

(http://workgoats.com/images/03-12-13_04a.jpg)

I have moved the winch to the rear bumper for this pic.  Sooner or later I will build a tailgate, probably a steel frame with a wood center.  I might get that done before Ram Jam.

(http://workgoats.com/images/03-12-13_05a.jpg)

The floor of the bed raises for access to two storage compartments.

(http://workgoats.com/images/03-12-13_06a.jpg)

The rear compartment is over the gas tank and has room for the steel winch cable (in case I cut the plasma rope), the winch controls, jumper cables, various hitches and a bunch of recovery stuff.

The front compartment holds the winch battery, the on-board air tank, the jack and has room for some spare parts.

(http://workgoats.com/images/03-12-13_07a.jpg)

The wheel base is the same as the axle donor vehicle, a 4 dr Cherokee.  Adding the cab and the bed make it look a lot bigger than it did before.  I did put a lot of weight in the bed and feel like it is now a lot better balanced.  I hope to tow it to the work location where I can drive it around on the private drive and in the woods.

That will have to wait several days as it is our spring break and we are headed to a state park for a few days.

(http://workgoats.com/images/03-12-13_08a.jpg)
Title: Re: Willyreplica from the start...
Post by: SixGun on March 13, 2013, 12:42:40 AM
Nice profile pic of the Willys.  Can't wait to see it painted like the rest.  It's like a whole different vehicle. :thumbsup:
Title: Re: Willyreplica from the start...
Post by: rjtx667 on March 13, 2013, 09:59:22 AM
that bed looks sharp  :13:
Title: Re: Willyreplica from the start...
Post by: workgoats on March 21, 2013, 10:19:04 PM
 :sleepy: (http://:sleepy:)
Title: Re: Willyreplica from the start...
Post by: rjtx667 on March 21, 2013, 10:54:34 PM
PAINT!!!! I see paint!!!

looks good  :13:
Title: Re: Willyreplica from the start...
Post by: SixGun on March 22, 2013, 02:16:19 AM
You gonna call it Ole Yeller ???   :13:
Title: Re: Willyreplica from the start...
Post by: workgoats on March 22, 2013, 05:47:02 AM
I had a 68 Dodge Dart GT that was that color.

My first name is William. Maybe it should be the "Yeller Willy".
Title: Re: Willyreplica from the start...
Post by: SixGun on March 22, 2013, 07:18:42 PM
Quote from: workgoats on March 22, 2013, 05:47:02 AM
Maybe it should be the "Yeller Willy".
Noooooooooo..... :nono:  You've got a sick mind Ron.

Maybe Free Willy   :laughing7:
Title: Re: Willyreplica from the start...
Post by: workgoats on March 22, 2013, 07:29:12 PM
Quote from: SixGun on March 22, 2013, 07:18:42 PM
Noooooooooo..... :nono:  You've got a sick mind Ron.

Maybe Free Willy   :laughing7:

Not a chance. Ain't been nothing free on this project.  What was free was erased by the amount of time spent.
Title: Re: Willyreplica from the start...
Post by: SixGun on March 22, 2013, 08:12:13 PM
yellow submarine??   :dontknow:
Title: Re: Willyreplica from the start...
Post by: ernestgonzales78@gmail.com on March 22, 2013, 09:06:16 PM
Dang its looking sharpe :13: :dance:
Title: Re: Willyreplica from the start...
Post by: crazzywolfie on March 22, 2013, 10:01:44 PM
that thing is looking good. i don't know about the yellow but i guess we will have to wait and see once it is done. i kind of like the green.
Title: Re: Willyreplica from the start...
Post by: SixGun on March 22, 2013, 10:07:17 PM
Yellow paint does look nice and pretty but I really liked the OD green too. 
Title: Re: Willyreplica from the start...
Post by: workgoats on March 27, 2013, 05:55:40 AM
The yeller is just spray cans.  When I get through "designing" and if it is worth driving around town, I will sand it all down put some filler in the bad spots and re-paint it.  Then we can see what the final color is.

My first new car was a 68 Dodge Dart GT and it was this color of yellow.  New out of the dealer for $3030.00
Title: Re: Willyreplica from the start...
Post by: rjtx667 on March 27, 2013, 08:27:30 AM
Quote from: workgoats on March 27, 2013, 05:55:40 AM
New out of the dealer for $3030.00


I wish it was back then still.... my transmission for the 2000 cost more than that, and don't even get me started on the paint or engine  :fucyc:
Title: Re: Willyreplica from the start...
Post by: SixGun on March 27, 2013, 10:37:01 AM
Well no wonder it was only 3 grand with yeller spray paint from the factory.   :laughing7:


Seriously, I think the yellow paint would look good with some black accents on it.  I know it's Easter season but don't make it too yellow. 
Title: Re: Willyreplica from the start...
Post by: workgoats on March 29, 2013, 09:10:04 PM
I have been working on it, almost every night.  I have basically finished the bed and the cab.  Still to go is a tailgate and some bed trim.  I will install a rear window in the cab and build some sort of sliding windows over the top of the doors.  I will have them removable for good weather and events.

Here it is, out on the driveway, driven by Ernest:

vimeo.com/62974503 (http://vimeo.com/62974503)
Title: Re: Willyreplica from the start...
Post by: taz_man440 on March 29, 2013, 10:04:14 PM
Have you started tryin to make it legal yet?
Title: Re: Willyreplica from the start...
Post by: workgoats on March 30, 2013, 05:26:56 AM
Quote from: taz_man440 on March 29, 2013, 10:04:14 PM
Have you started tryin to make it legal yet?

I'm getting close but won't start till after Hidden Falls. Insurance comes first and it will be time for a new insurance policy then. I will have to find an agent that will cover it.
Title: Re: Willyreplica from the start...
Post by: workgoats on March 31, 2013, 09:46:05 PM
Here are the pictures taken today.  It is now back in the garage.  I'll be putting the skid plate back on and finishing up a few things before we hit the trails on April 26th at Hidden Falls.

I used it today to get the rest of the red truck parts loaded and stored away in storage.

(http://workgoats.com/images/IMG_0327a.jpg)

The axles will go under the RC with the magnum engine and the throttle body off the 360 will go on the 318 in the "Tonka Willy".  Eventually the 360 may make its way there too.

The next picture shows a closer view of the second receiver for the winch.  This receiver is not directly attached to the frame but it will be strong enough to pull a vehicle up on the trailer (with the trailer attached to the truck).

(http://workgoats.com/images/IMG_0327-1a.jpg)

(http://workgoats.com/images/IMG_0328a.jpg)

And here is my truck and my daughter's XJ after taking the required Easter pictures by the pond.

(http://workgoats.com/images/IMG_0329aa.jpg)
Title: Re: Willyreplica from the start...
Post by: workgoats on April 06, 2013, 08:31:46 PM
So, check this out...

I will apply for a replica title.  I will request it to be a replica of a 1948 Willys Pickup.  If it was built after 1949 to represent a 1948 or earlier vehicle, is built from materials not used originally or modified in shape and the title says replica, then it can be licensed as a street rod.  It has to be inspected by an ASE mechanic to get the title. 

I have to document where the motor, frame and body came from.  Motor came from a vehicle that I now own so that won't be a problem.  I built the frame and body.

End result:  replica title, street rod plates = exempt from state inspection.  Go figure.  :icon_scratch: (http://:icon_scratch:)
Title: Re: Willyreplica from the start...
Post by: rjtx667 on April 06, 2013, 09:47:21 PM
wow crazy but kind of cool all at once... you now get a small return on your labor investment every year from not getting an inspection lol.
Title: Re: Willyreplica from the start...
Post by: workgoats on April 06, 2013, 10:34:38 PM
I put 100 feet of 3/8" plasma rope on my 12,000# winch.  100 feet of plasma rope weighs 3.7 pounds.  Minimum tensile strength is 17,500 pounds.  Seems pretty impressive.  I guess that is why we use it to lower expensive stuff to the bottom of the ocean.

I guess it will be okay to use it to winch Ernest's ferd up the hill.

I WILL NOT entertain the thought that the ferd might have to help my truck. :victory: (http://:victory:)
Title: Re: Willyreplica from the start...
Post by: taz_man440 on April 06, 2013, 11:11:53 PM
Ron, it would probably take 3 or 4 or us to get such a beast up a hill...lol
Title: Re: Willyreplica from the start...
Post by: rjtx667 on April 07, 2013, 09:19:04 PM
Quote from: taz_man440 on April 06, 2013, 11:11:53 PM
Ron, it would probably take 3 or 4 or us to get such a beast up a hill...lol

Why would we take it up the hill anyways? tell him to go use the bypass  :evil6:
Title: Re: Willyreplica from the start...
Post by: taz_man440 on April 07, 2013, 10:07:24 PM
Quote from: rjtx667 on April 07, 2013, 09:19:04 PM
Why would we take it up the hill anyways? tell him to go use the bypass  :evil6:

Well, drag it up the hill so he can get at least 1 picture of it going down the hill.. can't tell if its running or not in a pic....lol   

That would definitely be a watch this moment....
Title: Re: Willyreplica from the start...
Post by: SixGun on April 07, 2013, 10:28:52 PM
Yeah, I thought shit always rolled down hill.   :laughing7:

What???  Roll it like he stole it...  :tongue3:
Title: Re: Willyreplica from the start...
Post by: ernestgonzales78@gmail.com on April 08, 2013, 09:41:25 PM
Well its nice to see y'all love me so much. I hope y'all don't cry to much when ur trying to keep up.  :tongue3: :wave:
I did try to test it today at work. But there wasn't any real challenge. Did find that so far the locker is working and I can drive it locked in. Brakes work a lot better now. Put new system all the way around. Was tired of fitting with the hard pedal. I hope I get to make it. There is rumor that a job might go through about the same time we have planned. Work before playing is the rule.  :violent1:
Title: Re: Willyreplica from the start...
Post by: workgoats on April 10, 2013, 11:36:57 AM
Testing from my phone.
Title: Re: Willyreplica from the start...
Post by: workgoats on April 16, 2013, 08:21:02 PM
Well, after two days, Texas Farm Bureau decided that they could not insure my truck because they classify it as a "KIT CAR" and they don't insure kit cars.  This was after forwarding pictures and the entire build thread. :puke: (http://:puke:)

And to think, I spent a number of my years as an adjuster for Oklahoma Farm Bureau...

I will be trying someone else tomorrow.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on April 16, 2013, 09:48:27 PM
Interesting... I think its funny they had no issues insuring the 2000 RamCharger.

Sorry to hear about your issues.
Title: Re: Willyreplica from the start...
Post by: workgoats on April 22, 2013, 10:37:57 PM
Here are the photos I sent to the insurance company to get the policy in force:
Title: Re: Willyreplica from the start...
Post by: workgoats on April 30, 2013, 09:31:30 PM
I finally got a chance to wash off some of the mud on the truck.  I found a bent right side spring mount on the rear axle.  I had "add supports" on my to-do list that didn't get completed.  I will be rebuilding both sides now so this won't happen again.
Title: Re: Willyreplica from the start...
Post by: workgoats on May 04, 2013, 06:42:52 AM
I found that the front spring mounts were a little weak. Beefing them up was next on my list but didn't get done.

I bent the one on the right side when I set all the weight on the front on the spring on "Feeder Creek", right before Richard started up behind me.

I will be rebuilding them. I will also be installing some BP stops on the rear axle and some kind of limited slip in the rear axle before RJ.
Title: Re: Willyreplica from the start...
Post by: Toyradio on May 05, 2013, 06:53:11 PM
Sounds like you need to get off the couch and get busy. Need some help let me know. I have the time to come give you a hand.
Title: Re: Willyreplica from the start...
Post by: workgoats on May 08, 2013, 11:04:53 PM
No pictures but see if you can picture this in your mind.  Right rear spring, front mount, bent on rock on Feeder Creek.  New mount built and installed, welded to both tube frames.

Blind nut, welded in back, against the frame.  After a night of fabrication, and a night of being unable to get the bolt installed...   :angry4: (http://:angry4:)

1.  frame on jack stand
2.  wheel off and floor jack under axle
3.  cable hoist from left rear spring to right rear spring to pull inward
4.  cable hoist from rear axle to chain to front frame to pull forward
5.  straight tire tool controlled by scissor jack on top of spring to lower inner side of spring eye
6.  tap on bolt with claw hammer while turning with crescent wrench

Done!   :13: (http://:13:)
Title: Re: Willyreplica from the start...
Post by: rjtx667 on May 09, 2013, 09:46:19 AM
sounds like we needed a video of that.

what kind of sacrifice did you offer before you began?  :laughing4:
Title: Re: Willyreplica from the start...
Post by: workgoats on August 08, 2013, 03:35:03 PM
Well, I have insurance and a 30 day permit to drive the thing on the road.  I still have a couple of loops to jump through and some cash to come up with for the tags, but at least I can drive it some now.
Title: Re: Willyreplica from the start...
Post by: SixGun on August 08, 2013, 06:57:23 PM
 :PDT_Armataz_01_37:  Alright it's been a long time coming.  Soooo ... you gonna drive it to Ram Jam?
Title: Re: Willyreplica from the start...
Post by: workgoats on August 12, 2013, 02:18:09 PM
Quote from: SixGun on August 08, 2013, 06:57:23 PM
:PDT_Armataz_01_37:  Alright it's been a long time coming.  Soooo ... you gonna drive it to Ram Jam?

Not likely but I suppose possible.
Title: Re: Willyreplica from the start...
Post by: workgoats on December 22, 2013, 08:53:57 AM
It says nothing has been posted here in 120 days. I have a tag, just not a title.  I've put just over 3000 miles on it so far. But, it's not the end yet.

I'm still slowly working on really having a title.  I did all the paperwork they asked for but then they decided that I have to take it to Conroe to have a cop inspect it and they want a Manufacturer's Certificate of Origin or a bill of sale on the body.  I sorta still have a business, (Aggieland Working Goats), that used to do petting zoos.  I think it will now be the manufacturer of one Jeep pickup body. 

After the last trip to Hidden Falls and the bind that Ernest and I put it in before anyone else got there I had to do some work on the back springs.  It already had an add a leaf from Iron Rock Offroad and I added an additional leaf from the spring pack on a 78 Cherokee.  I like the stance now and the suspension is stiff enough to pull the stock trailer and large horse of my grand-daughters to functions now.  When we got it in trouble we also broke one of the wedges that clock the rear axle to the constant velocity joint.  I have replaced those with steel instead of aluminum and increased the bolt size from something metric to 3/8" grade 10.

I suppose the extra springs will make it have less articulation but pulling the horse to the barrel races is pretty important too. 
Title: Re: Willyreplica from the start...
Post by: SixGun on December 22, 2013, 10:10:34 PM
Did you have a title on the Red Beast?  If so, how did you do that one?
Title: Re: Willyreplica from the start...
Post by: workgoats on December 23, 2013, 06:00:22 AM
I was driving it as a RC. I didn't bother to tell the state when I replaced the body. I only had liability insurance and the body never became an issue, even after a major wreck.
Title: Re: Willyreplica from the start...
Post by: workgoats on February 03, 2014, 09:10:13 PM
I like the added spring.  My Holley 4 banger has been acting up.  I have borrowed another and it's not any better.  I won't have cash for a while due to family stuff coming up so I may be driving the Cherokee for a while.

Title: Re: Willyreplica from the start...
Post by: workgoats on February 09, 2014, 07:31:29 PM
Ok, so I am so tired of carburetors... 

I have pulled out the 90 intake manifold off the red truck, fitted the throttle body and the sensors that it needs and started wiring the megasquirt to go in the yeller truck.  Fuse block and relays for the system are built.  I have the Hall Effect distributor.  I have the fuel pump and both lines from the tank to the engine compartment are already in place.

The computer is built and ready to go.  All I need now is some gaskets, some room to get the truck back in the garage and about 3 days to swap it, change the electrical and then about two more weeks to figure out how to tune it.  Only problem is that the family wants some stuff done too.

I need a Dodge temp sender for the computer and a early CJ temp sender for the dash panel.

The way the computer is set up, I will read the crank position from the distributor, and use the map sensor that is in  the computer.  It uses one oxygen sensor and the truck already has that installed with the 90 exhaust manifolds.

I hesitate to start because the Cherokee is making some wheel bearing noise and I can't have them both down at the same time.
Title: Re: Willyreplica from the start...
Post by: workgoats on April 13, 2014, 09:27:50 PM
Okay, I should have rebuilt the tranny when I started.  After 5k miles it decided to cough up some really neat stuff in the pan.

I have another transmission but it was attached to the 360 Magnum.  So, now the yellow truck is missing the engine, transmission, transfer, skid plate, exhaust, driveshafts, floor, seats and gas tank.

Nick and I had built a RC gas tank to hold the fuel pump for the 96 magnum.  I made room for it in the back of the truck and when I pulled it there were cracks across the top of the tank.  So, I rebuilt one I had in the storage building.  I don't have any idea where it came from but it was built in 1986.  The other was a 1982 tank so I guess it should be good for 4 years.

I have some wiring revisions to do before I start on the Magnum installation but it should fit without too much problem.

I will have to use the exhaust manifolds from the 1990 360 because there is not room for the rear exit pipes.  The y pipe I have will have to be used and it is too small for the engine but there isn't room to increase the pipe size.

One other problem is the onboard air.  I will be going back to a York unit instead of the RV2 that I have been using because I have been unable to locate a serpentine pulley or clutch for the compressor.  Some Yorks had a serpentine pulley and a new one can be found from several places.  If anyone has info on adapting a serpentine pulley for the RV2, please let me know.

Title: Re: Willyreplica from the start...
Post by: ProjectPW on April 15, 2014, 08:30:20 AM
lookin' good  :great: ...... now lets go wheel it  :steeringwheel: a little moon dust/trail rash on top of some fresh wax......... :headbang:
Title: Re: Willyreplica from the start...
Post by: workgoats on April 26, 2014, 08:52:45 PM
Here's where I am now:

360 magnum, wired to batch fire using Megasquirt 2+
360 TBI exhaust manifolds and too small of an exhaust system
727 modified to fit the magnum
242 Jeep transfer
86 RC gas tank modified with 96 fuel pump and no return fuel lines

left to do:
lower radiator hose
one heater hose
adjust bands and change filter on tranny
install tranny pan WITH DRAIN PLUG
install floor over tranny and transfer
install transfer shifter
install inverter
install computer
install driveshafts
heat shield over steering shaft
install batteries and relocate battery cable to front winch plug

Then all I will have to do is figure out why it won't start...
Actually, it should start but there will be a lot of setup left on the computer program.  It should continue right from where Nick and I stopped when it was in the RC if I did the harness swap correctly.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on April 26, 2014, 09:55:30 PM
Let us know when you get that close, between Noah and myself we should be able to get you going.

The one thing we talked about, and agreed on, is you need a wide band fuel sensor. They are not real cheap, but without it you will never get it close enough to be what you want it to be.

When you are there, I have the one from the 2000 charger, I plan to play with it a little on the 13 durango R/T if they ever decide to support it... but thats not a major need so it can always be shipped out and borrowed to get yours running good.
Title: Re: Willyreplica from the start...
Post by: workgoats on April 27, 2014, 09:17:41 PM
I know that the configuration that we started with in Nick's RC was using the O2 sensor from the 96 Dodge.  We only used the front sensor.  I don't have a complete catalytic converter so I don't see any reason to use 2 sensors.

I don't know much about these sensors but it seems to me that if I use a wide band sensor there is a controller involved.  Am I reading something into this that isn't there or do I need a controller also.  If I use a controller, what kind of wiring is needed to make this work?

I am getting close to hooking the computer up and starting on this.  Engine is ready except for the bottom radiator hose which will take some looking at NAPA or splicing two together to attach it to the non standard radiator.  I have to get some more heater hose but that's a no problem there.  I have oil in the engine and transmission.  I think all wiring is complete but I haven't put the battery (-ies) back yet.  I have power steering hooked up, even though the clearance with the fender is close.

I will be without on board air for a while, but I have a good York 210 compressor and there are clutches for it that will fit the serpentine belt.  When I get it ready I will fabricate a bracket to install it where the factory compressor is now.

I went out and took some pics of the engine compartment.  I'll post them shortly.
Title: Re: Willyreplica from the start...
Post by: workgoats on April 27, 2014, 09:56:21 PM
Okay, here's a couple of views, from both sides of the truck.  I couldn't use the magnum's air cleaner without an air scoop in the hood.  Not going to happen.  The air cleaner from the 90 TBI engine fits and there is a threaded hole in the throttle body of the magnum.  It's just not in the center.  This will take a little fabrication but should look as good as the rest of it.

I had to use the exhaust manifolds off the TBI engine as well because there was not enough room for the rear outlets and the way I built the body.

The third picture shows the wiring for the engine operation.  Top arrow is the starter solenoid.  It's stock except for the removal of the wire to the ballast resistor.  Second arrow shows the fuses for the computer, injectors, O2 sensor and fuel pump.  Red arrow shows the location of the solenoids for megasquirt (under the haynes manual).

The fourth picture shows the limited clearance at the power steering.  I suspect that when the hose wears a hole in itself, I will modify the fender.  The red arrow shows the solenoids for megasquirt.
Title: Re: Willyreplica from the start...
Post by: workgoats on April 27, 2014, 10:06:26 PM
opps.  I didn't get the right side pic re-sized.

I'll try again.

The last picture shows the front of the engine.  I hope to replace the stock compressor with a York compressor for on board air.
Title: Re: Willyreplica from the start...
Post by: Dracen on April 30, 2014, 09:50:00 AM
Sure looking good Ron. I should do a custom body over my 97 Cummins ... Body is kind of beat up.... I think you saw it at ram jam... But right now I'm also thinking about swapping the axles into my new black truck... Mindy.... Then just parting out the rest of the diesel I simply don't use it and no way I would even get close to the amount I have invested. 3800 into the fuel system alone.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on April 30, 2014, 10:14:33 AM
I have something that might help your air cleaner, it came with my 58mm throttle body, its a bent rod so you can screw an air hat into to TB.

PM me your address and I can send it to you.

As far as the wide band o2, yes there is a controller that you wire up and reads the sensor. I have the complete package. It will work with a ODB II setup or you can just plug it in via serial port to your laptop and get the data from there.

I would not be surprised if Mega Squirt had a way for it to connect, but I am not sure.

Its from innovative motorsports, pretty popular brand.

I have more tuning to do on the 2000, but it will be a while since I need to figure out how to hunt down vacuum leaks. Your more than welcome to borrow the sensor if you want. just need an extra o2 bung welded into your exhaust.
Title: Re: Willyreplica from the start...
Post by: ProjectPW on May 01, 2014, 07:45:52 AM
Hey Ron ditch the crappy stock O2 sensor you dont need it....The lc1 wideband controller from Innovate motor sports will make your tuning adventure much more rewarding....Megasquirt fully supports the LC1 controller and it will allow you to build really nice AFR maps and get the autotune feature of Megasquirt actually working  :great:
Title: Re: Willyreplica from the start...
Post by: workgoats on May 05, 2014, 12:17:55 AM
Quote from: ProjectPW on May 01, 2014, 07:45:52 AM
Hey Ron ditch the crappy stock O2 sensor you dont need it....The lc1 wideband controller from Innovate motor sports will make your tuning adventure much more rewarding....Megasquirt fully supports the LC1 controller and it will allow you to build really nice AFR maps and get the autotune feature of Megasquirt actually working  :great:

Right now I'm just trying to get it running.  It was marginally running but I found that we had not populated all of the configuration data.  We did not put in any info on the injectors.  Right now I'm concerned about the ignition setup.  I've asked some questions on the MS board. 

I will go to the wide band O2 but it can't happen for a few paychecks.

Here's the basic questions:

MS 2357-C
MS2 Extra ECU w/PCBv3.67
MS Extra 3.1.1

Stock Hall effect crank sensor (60 deg)
fire directly to coil
injectors fire in two batches, side to side

What should the spark mode be?  (Basic Trigger, toothed wheel or what)
What ignition input capture should I use?  (rising edge or falling edge)
What should the spark output be?  (going high or going low)
Should I use fixed advance or table?
Should I use prediction?

It started and ran without the injector info but it was rough and mis-firing at 4000 rpm or so.  It would idle one time and the next time try to run at 3000rpm.

I failed to record a log at that time.  Now I can't get it started.   :dontknow: (http://:dontknow:)

Today I have been working on electric windows.  I'll have to do a build on this because it is so simple if you don't mind a small amount of fabrication.
Title: Re: Willyreplica from the start...
Post by: ProjectPW on May 05, 2014, 05:22:27 PM
Sorry Ron I can't help much on you spark issues...my only venture into Megasquirt land has been a fuel only setup. I have used a standard mechanical advance distributor using an Gm hei module for spark control and output signaling for the megasquirt ecu. It is pretty fool proof and it let me focus learning how to tune the fueling without worrying about the spark being right.
Title: Re: Willyreplica from the start...
Post by: workgoats on May 06, 2014, 10:06:05 PM
Spark problem is not solved but it is running quite a bit better.  I think it is probably firing every 360 degrees instead of every 720 degrees.

I would take it out for a spin if it wasn't for rewiring the cameras, re-positioning a brake line, finishing the electric windows, re-positioning the seat belts, replacing the door handles with ones that really lock, and now...

The transmission is leaking from the seal around the shifter shaft.  Seal won't be here till tomorrow and the way I built the thing, I may have to pull the floor again to get to the seal.

Plus, seats are in the floor.  Fan is bigger that the last one so I have to build a shroud.  I already had a pencil go through the fan.  I don't want it to throw something through the radiator, especially a finger or something like that.
Title: Re: Willyreplica from the start...
Post by: workgoats on June 04, 2014, 07:32:07 PM
Internet has been down for a week.  Here's an update.  Magnum 360 is running with the MegaSquirt II Extra computer.  I'm using a 90 distributor (TBI) for a signal from the cam sensor and have disconnected the crank sensor.

I still have some issues with idle and acceleration but I'm gaining.

One big problem was when I had the rotor in backwards and it backfired loud enough that the cops came to check for gunfire.  My next door neighbor is a cop and he was asleep at the time.  I don't think he called it in but who knows...

I have some real compatability problems between the 1996 gas sender in the tank and the 60's Jeep gas gauge.  Anybody got any suggestions?
Title: Re: Willyreplica from the start...
Post by: Dracen on June 06, 2014, 09:54:38 AM
Might have to look up the voltages range for both and see if you can adjust them to match with resistors buth thats only if the 96 is higher output but if its lower then you may not have a choice but to replace one or both.
Title: Re: Willyreplica from the start...
Post by: workgoats on June 08, 2014, 08:22:27 AM
The gas tank is a modified 80's RC tank with the fuel pump out of the 96 pickup.  I had to remove the added ring and re-seal it so while doing so I installed a boat tank sender in the vent hole.  There is a second vent location in the fuel pump assembly.  Both senders work but have different resistance.  At worst, I can use a gauge for a boat.

On another note...  I took it out for a ride down the highway and brought it back with the tow bar.  Seems that one of the transmission cooling lines gave up the ghost at 70 mph.  It sprayed fluid all over the exhaust.  I guess I'm lucky I didn't set it on fire.  There will be less mosquitoes along Hwy 6, though, after the smoke clears. :toothy9:
Title: Re: Willyreplica from the start...
Post by: The War Wagon on June 08, 2014, 02:31:27 PM
Quote from: workgoats on June 08, 2014, 08:22:27 AM
On another note...  I took it out for a ride down the highway and brought it back with the tow bar.  Seems that one of the transmission cooling lines gave up the ghost at 70 mph.  It sprayed fluid all over the exhaust.  I guess I'm lucky I didn't set it on fire.  There will be less mosquitoes along Hwy 6, though, after the smoke clears. :toothy9:




Sorta like this?  :o




http://www.youtube.com/watch?feature=player_embedded&v=8ls_fn--uFc
Title: Re: Willyreplica from the start...
Post by: workgoats on June 09, 2014, 03:56:00 PM
Yeah, it was a lot like that.  Should have seen the cars trying to figure out how to get out from behind me.
Title: Re: Willyreplica from the start...
Post by: rjtx667 on June 11, 2014, 07:12:35 PM
Never a dull day with old toys is there :laughing7:
Title: Re: Willyreplica from the start...
Post by: ProjectM880 on September 18, 2014, 12:28:28 PM
Whats the Verdict? Is the WillysReplica going to be ready in October??
Title: Re: Willyreplica from the start...
Post by: workgoats on September 19, 2014, 11:39:11 PM
Waiting on some good suppression plug and coil wires coming tomorrow.  If it straightens out the signal from the throttle position sensor I should be able to bring it.
Title: Re: Willyreplica from the start...
Post by: workgoats on July 26, 2015, 09:39:49 PM
I've given up on dealing with the state on this vehicle and a title.  I am looking now at moving the front end and part of the drive train to the 97 ZJ that we used as a parts car.  I have a clean title on that jeep.  That would be changing the rear suspension to a four link suspension, using part of the Grand Cherokee floor pan and ending up lower to the ground but probably more trail worthy vehicle.  There are also engine mounts for the 360 readily available to put it in the vehicle.

The 97 is a 2 wheel drive so I would have to move the axle from the yellow truck to the Grand Cherokee.  It's a straight axle (NO CAD) and has the same gears.  It would end up as an open car for the trail or good weather in a college town.
Title: Re: Willyreplica from the start...
Post by: workgoats on July 26, 2015, 09:41:08 PM
Does anyone know if the fuel pump in the 97 Grand Cherokee fuel tank would put out enough to support a 360 Magnum engine?
Title: Re: Willyreplica from the start...
Post by: ProjectPW on July 27, 2015, 08:12:48 AM
Quote from: workgoats on July 26, 2015, 09:41:08 PM
Does anyone know if the fuel pump in the 97 Grand Cherokee fuel tank would put out enough to support a 360 Magnum engine?

Yes it should  :thumbsup: