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TECHNICAL FORUMS => Project Builds => Topic started by: Wingman on March 02, 2014, 08:46:20 AM

Title: Willys MB build
Post by: Wingman on March 02, 2014, 08:46:20 AM
The secret build revealed!

Some know that I've been shopping for "random" parts and asking unusual questions that would lead one to believe that a super-secret project was afoot.  Those who had to be made privy were sworn to secrecy.  A heavy burden...

After much reading, image reviewing, and deliberation, I think I've finally come to the conclusion that my next project will be a ground-up custom Willys MB build, for "wreck" and road only.  I've always loved the reputation and appearance of the WW2 Willys Jeep.  Not quite buggy status (I'll probably regret this later) but a build that will only use the grille and hood from the real thing.  The body dimensions will remain intact with a slight front clip extension to make room for the drivetrain.  The goal is to remain small and as lightweight as possible and keep all of the look of an American classic.  While not a thorough-bred, a tribute none the less.  May have to add some real bullet holes, err, I mean, speed holes.

Couple of inspirational pics:
(http://www.twistedandes.com/foro/attachment.php?attachmentid=87174&stc=1&d=1277083577)
(http://i85.photobucket.com/albums/k62/mike_gardner/E4378BB3-F1F0-4A1B-8496-D0AF337BE873-752-000000B94C0A6102_zpse91e3ba6.jpg)
(http://image.4wheeloffroad.com/f/9337361/p61185large+jeep+side_view.jpg)

Starting points:
D44 front w/RCVs
Ford 9' HP rear
D300 t-case
5.3 aluminum LS
4L60E
4-link rear?
3-link front?
coilovers?
flat belly ~20"
2x4 box frame
integrated full cage
tin body panels
36-37" tire/wheel combo
full hydro steering
~86-87" wheel base
dropped seating
lower windshield and cage height
low COG
road legal

Think "big kid's go-cart" (borrowed phrase)

Always open to words of encouragement, criticism, tech wisdom, and heckling.

So, there it is.  Now to collect some more parts, tools, material, and ambition...
Title: Re: Willys MB build
Post by: MrMindless on March 02, 2014, 10:19:02 AM

I see what you're after with the lighter axles and case but for the price of a RCV'd 44 you could probably be close to a 9" front running stock or cromo 60 shafts. Lighter and stronger than the 44.


Nobody should ever use a 44 in something it isn't already under :)


Tapatalk (http://tapatalk.com/m?id=1)ing in traffic
Title: Re: Willys MB build
Post by: Wingman on March 06, 2014, 05:26:08 PM
One of the few OEM pieces arrived today

(http://i132.photobucket.com/albums/q17/wingman0/100_5766.jpg)
Title: Re: Willys MB build
Post by: jACeL86 on March 07, 2014, 04:55:09 PM
I'll only heckle out of jealousy.  :D
Title: Re: Willys MB build
Post by: Wingman on March 18, 2014, 11:37:25 AM
Steel delivery...

(http://i132.photobucket.com/albums/q17/wingman0/100_5776.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 19, 2014, 06:57:10 PM
Frame rails

(http://i132.photobucket.com/albums/q17/wingman0/100_5778.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 20, 2014, 04:08:45 PM
Today's progress = reinforcement plates

I need a plasma cutter.

(http://i132.photobucket.com/albums/q17/wingman0/100_5779.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/100_5780.jpg)
Title: Re: Willys MB build
Post by: etk300ex on March 21, 2014, 10:09:20 AM
Big dogs?  :). Looks good!
Title: Re: Willys MB build
Post by: Wingman on March 21, 2014, 04:20:53 PM
Fun with levels, tape measures, squares, jackstands, spare parts, and such today...

YJ leaves I picked up are rusty piles of broken-ness.  I guess I'll be ordering new waggy leaves.  Was leaning toward front leaves for simplicity.

Grille just set in for thickness reference.  Too low in current position but will likely be down between the rails some.  Leaving space in front for recessed winch.

Looks like final length should be around 127-129".  That's 13" off of existing rails.  86-88" wheel base.  With 36" tire, around 21" belly.

(http://i132.photobucket.com/albums/q17/wingman0/100_5783.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 22, 2014, 05:15:35 PM
Ruffstuff goodness arrived.

Front spring hangers and shackle bushing, rear 4-link kit.

(http://i132.photobucket.com/albums/q17/wingman0/100_5784.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 24, 2014, 04:18:23 PM
Front spring mount tacked, YJ leaves slung, axle moved into place.

Have to rethink my current axle selection, they're wider than I thought.  It's a crying shame too because they are almost perfect in every other way.

(http://i132.photobucket.com/albums/q17/wingman0/100_5796.jpg)
Title: Re: Willys MB build
Post by: jACeL86 on March 25, 2014, 05:20:37 PM
You are wasting zero time! Nice!
Title: Re: Willys MB build
Post by: Wingman on March 27, 2014, 02:12:43 PM
Not a lot of progress in the last couple of days.  Still trying to figure the rear 4-link layout.  And haven't been feeling good...   :-\

Did get the upper axle mount welded up yesterday.

(http://i132.photobucket.com/albums/q17/wingman0/100_5798.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 28, 2014, 07:37:07 AM
A little mock-up, not the correct outer bracket:

(http://i132.photobucket.com/albums/q17/wingman0/100_5799.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 31, 2014, 05:25:49 PM
Special delivery of a VIP (Very Important Part) yesterday.

LM4 aluminum block (pre-L33), 40k miles, 290 hp, 325 f/lbs torque, "drive-by-wire"

Needs a pan change, intake should be fine.  We'll see.

(http://i132.photobucket.com/albums/q17/wingman0/100_5800.jpg)

New pan (4/4/14).  Corvette C6 new take-off.

(http://i132.photobucket.com/albums/q17/wingman0/100_5803.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 03, 2014, 07:08:19 AM
Rebuilt 4L60E acquired yesterday.  It looks dirty but I think it was painted black at some point.

(http://i132.photobucket.com/albums/q17/wingman0/100_5802.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 12, 2014, 07:00:01 PM
More from Ruffstuff today.  Frame side link mounts, cross member mount/bushing kit, axle housing weld-on flanges, and LS engine mounts.

(http://i132.photobucket.com/albums/q17/wingman0/100_5804.jpg)

Finished welding up and tacking on rear link mounts.

(http://i132.photobucket.com/albums/q17/wingman0/100_5805.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 14, 2014, 09:48:41 PM
Rocker work today.  Two more supports to be installed.

(http://i132.photobucket.com/albums/q17/wingman0/100_5807.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 16, 2014, 04:49:43 PM
Now with matching rockers...

This one gave me a little trouble getting it leveled and positioned  >:(
(http://i132.photobucket.com/albums/q17/wingman0/100_5809.jpg)

Also bent my first piece of (practice) tube
(http://i132.photobucket.com/albums/q17/wingman0/100_5808.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 18, 2014, 05:21:14 PM
Bent more tube.  Much better with big compressor.  Way too fun.  Measure 50 times, bend once.

Kind of starting to look like something.  Not sure what, but something.

(http://i132.photobucket.com/albums/q17/wingman0/100_5812.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 23, 2014, 07:28:06 AM
Another hard part arrived today...

rear TrueHi9, 5.38s, Grizzly, 1350
(http://i132.photobucket.com/albums/q17/wingman0/100_5815.jpg)
Title: Re: Willys MB build
Post by: Callelle on April 23, 2014, 09:03:34 AM
I want one >.>
Title: Re: Willys MB build
Post by: Wingman on April 24, 2014, 04:08:04 PM
Did some cleaning/organizing, dug my engine crane out of the corner and assembled, changed the engine oil pan, mated the trans to the engine, and slung the combo into the frame.  Mounts yet to be fabbed.  If I maintain the flat belly idea, the intake will need to be changed.  It's tall.

(http://i132.photobucket.com/albums/q17/wingman0/100_5819.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 26, 2014, 09:49:42 PM
Keith stopped by today and we got the windshield hoop and a couple of stringers in.

(http://i132.photobucket.com/albums/q17/wingman0/100_5820.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 27, 2014, 09:23:55 PM
Acquired a set of DRW C&C GM axles today for parts harvesting (inner "C"s, knuckles, spindles).  Front might serve as an interim unit pending budget.  Rear has nothing useful to me.  Too bad because it is 63.5" wms.  Reasonably priced SRW stuff is getting pretty scarce...

(http://i132.photobucket.com/albums/q17/wingman0/100_5821.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 29, 2014, 03:25:04 PM
Brown truck delivered some more goodness this morning.  Yukon D60 spindles and Stage 8 spindle nuts.

(http://i132.photobucket.com/albums/q17/wingman0/100_5823.jpg)
Title: Re: Willys MB build
Post by: Wingman on May 01, 2014, 04:23:17 PM
Finished up door tubes, roof stringers, and rear struts.  Even got my rattle can out.

(http://i132.photobucket.com/albums/q17/wingman0/100_5825.jpg)
Title: Re: Willys MB build
Post by: Wingman on May 02, 2014, 02:27:34 PM
AA trans to t-case adapter and D60 hub assemblies arrived today.

(http://i132.photobucket.com/albums/q17/wingman0/100_5829.jpg)
Title: Re: Willys MB build
Post by: Wingman on June 05, 2014, 07:32:20 AM
Got back to work the last couple days.  Engine mounts done.

(http://i132.photobucket.com/albums/q17/wingman0/100_5833.jpg)

There will be a removable crossbar connecting each once I borrow a bender again.
Title: Re: Willys MB build
Post by: Wingman on June 07, 2014, 04:18:57 PM
Installed the new AA input gear into the t-case, temporarily bolted on the adapters, and test-fit the combination.  Looks like I'll be playing with some custom clocking a bit to see what will give me the best-scenario clearance.  The adapter came with two choices and the "flattest" one is still about 1.5" below belly line and tight in every way.  Trans pan and likely some of the case will need clearancing.

(http://i132.photobucket.com/albums/q17/wingman0/100_5836.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/100_5837.jpg)
Title: Re: Willys MB build
Post by: Wingman on June 13, 2014, 04:34:39 PM
UPS *girl* dropped off this little 98 lb beauty...

(http://i132.photobucket.com/albums/q17/wingman0/photo1-1.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/100_5838.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/100_5839.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/100_5840.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/100_5841.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/100_5842.jpg)
Title: Re: Willys MB build
Post by: etk300ex on June 13, 2014, 04:56:12 PM
Ooooooo
Title: Re: Willys MB build
Post by: Wingman on June 18, 2014, 05:58:21 PM
Trimmed and tacked on axle-side upper and lower control arm mounts
(http://i132.photobucket.com/albums/q17/wingman0/100_5844.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/100_5845.jpg)

Looks like the rear shaft will be 17-18" with a <15* angle after the super short tail shaft
(http://i132.photobucket.com/albums/q17/wingman0/100_5843.jpg)
Title: Re: Willys MB build
Post by: Wingman on June 19, 2014, 03:47:47 PM
More Ruffstuff today.  Pinion guard, axle seals, clevis mounts, brake line brackets...
(http://i132.photobucket.com/albums/q17/wingman0/100_5847.jpg)

Fully welded the control arm mounts on the axle housing and spray-bombed.

Lower welds look OK.
(http://i132.photobucket.com/albums/q17/wingman0/100_5848.jpg)

Upper welds not great.  Hopefully "gorilla" quality.
(http://i132.photobucket.com/albums/q17/wingman0/100_5849.jpg)

And installed the axle seals...
Title: Re: Willys MB build
Post by: Wingman on June 20, 2014, 04:13:01 PM
Links!

(http://i132.photobucket.com/albums/q17/wingman0/6-20-14.jpg)

...and some hand-crafted machining.

(http://i132.photobucket.com/albums/q17/wingman0/6-20-142.jpg)
Title: Re: Willys MB build
Post by: GBR928 on June 20, 2014, 04:13:35 PM
That is a sweet housing!


Sent from my iPhone using Tapatalk
Title: Re: Willys MB build
Post by: Wingman on July 10, 2014, 07:38:36 PM
Took more than a month to get these...

Mastercraft Rubicon suspension series
(http://i132.photobucket.com/albums/q17/wingman0/photo1-3.jpg)
Title: Re: Willys MB build
Post by: Wingman on July 14, 2014, 01:19:39 PM
Shed some weight by swapping to 3/4 ton calipers and rotors by using TMR brackets.  Only hitch was the need to drill out the rotor stud holes to 11/16".  Same plan for the front.

D44 rotor on the left, D60 rotor on the right
(http://i132.photobucket.com/albums/q17/wingman0/photo2-1.jpg)

Teaser...
(http://i132.photobucket.com/albums/q17/wingman0/photo1-4.jpg)
Title: Re: Willys MB build
Post by: etk300ex on July 14, 2014, 05:18:16 PM
How much weight?
Title: Re: Willys MB build
Post by: Wingman on July 16, 2014, 09:03:23 PM
I'll have to amass the parts and measure at some point.  I think I read about 41#/corner (rotor, caliper, bracket, pads).

Novak order arrived today.

Teraflex Low300 kit (http://www.novak-adapt.com/catalog/transfer_case_parts/kit_low300.htm) and Novak super short HD output shaft (http://www.novak-adapt.com/catalog/transfer_case_parts/300rx.htm).

(http://i132.photobucket.com/albums/q17/wingman0/100_5864.jpg)
Title: Re: Willys MB build
Post by: etk300ex on July 17, 2014, 11:29:25 AM
41/corner get out of town!
Title: Re: Willys MB build
Post by: smichaelR22 on July 17, 2014, 11:54:08 AM
ya deff on my weight reduction list for KOH! lol
Title: Re: Willys MB build
Post by: gCracker on July 17, 2014, 12:53:49 PM
Quick research says 40lb overall weight reduction, not at each corner
Title: Re: Willys MB build
Post by: Wingman on July 18, 2014, 08:40:31 AM
Aaron is correct, 21# per corner.  (caliper bracket, rotor, caliper, no pads)  34# vs 55#.
Title: Re: Willys MB build
Post by: etk300ex on July 18, 2014, 08:59:19 AM
Ill buy that
Title: Re: Willys MB build
Post by: Wingman on July 27, 2014, 07:31:49 AM
Newest plan is to make a hybrid Ford 9" steer axle using Dana 60 parts.

GM D60 cut up and parts harvested.  It's still heavy!

(http://i132.photobucket.com/albums/q17/wingman0/photo5.jpg)

Using a pretty standard F9 housing for now since Ruffstuff is still not taking new orders for their custom housing.  Most parts will transfer over when obtained.  F9 housing gutted and brackets removed.

(http://i132.photobucket.com/albums/q17/wingman0/photo6.jpg)

Rollers mounted on rear, waiting for inner Cs to be machined for F9 tube diameter, housing ends cut to approx width, leaf springs removed, housing slung.  ~28" lower link length (90" WB).  Things get a little tight near the oil pan...

(http://i132.photobucket.com/albums/q17/wingman0/photo1-5.jpg)
Title: Re: Willys MB build
Post by: Wingman on August 19, 2014, 06:34:33 AM
The Cs I took off of the D60 came back today and were fitted to the present F9 housing and tacked at 10* pinion/8*+ caster.

(http://i132.photobucket.com/albums/q17/wingman0/photo2-3.jpg)
Title: Re: Willys MB build
Post by: Wingman on August 30, 2014, 05:21:17 PM
Finally getting back to this thing.  Been stupid busy lately.

Played with tubing roller today since Pacemaker finally got my stick of 1" delivered Friday.
(http://i132.photobucket.com/albums/q17/wingman0/100_5882.jpg)

...turned into inner fender structure.
(http://i132.photobucket.com/albums/q17/wingman0/100_5883.jpg)
Title: Re: Willys MB build
Post by: ollllllo on August 30, 2014, 06:59:52 PM
doesn't look like alot of room left for storage?
Title: Re: Willys MB build
Post by: Wingman on August 30, 2014, 07:26:55 PM
Hahaha.  Storage in a MB?  You're funny.

That's why they always had all of those things hanging off the outside.  ;D
Title: Re: Willys MB build
Post by: ollllllo on September 02, 2014, 07:04:18 AM
[emoji12]
Title: Re: Willys MB build
Post by: Wingman on September 13, 2014, 07:01:25 PM
Back in the shop this afternoon...

Trans/t-case crossmember and mount completed and holding weight!
(http://i132.photobucket.com/albums/q17/wingman0/Willystransmount1.jpg)

(http://i132.photobucket.com/albums/q17/wingman0/Willystransmount2.jpg)

(http://i132.photobucket.com/albums/q17/wingman0/Willystransmount3.jpg)
Title: Re: Willys MB build
Post by: Wingman on September 18, 2014, 01:16:33 PM
Delivered today...

(http://i132.photobucket.com/albums/q17/wingman0/Willysfronthousing.jpg)
Title: Re: Willys MB build
Post by: Wingman on September 20, 2014, 05:27:42 PM
Today's progress report:

King pin kits from East Cost Gear Supply.  Fast shipping - 2 days!
(http://i132.photobucket.com/albums/q17/wingman0/Kinpinkit.jpg)

Spent 40 minutes with a blasting cabinet this morning.
(http://i132.photobucket.com/albums/q17/wingman0/knuckles2.jpg)

Dry-fit for dim confirmation before long side cut.
(http://i132.photobucket.com/albums/q17/wingman0/knuckletempinstall.jpg)

King pin and lower race installed.  Caster set.  Ready for welding.
(http://i132.photobucket.com/albums/q17/wingman0/ReidinnerC.jpg)

Comparison.  Photo trickery makes "old" look much longer.  Only ~1.5" shorter.
(http://i132.photobucket.com/albums/q17/wingman0/frontaxlecompare.jpg)

Temporarily home.  Link brackets next.  Never mind that leaf spring hanger...
(http://i132.photobucket.com/albums/q17/wingman0/frontaxleteaser.jpg)
Title: Re: Willys MB build
Post by: etk300ex on September 22, 2014, 01:42:23 PM
That's a big ole pumpkin!
Title: Re: Willys MB build
Post by: Wingman on September 22, 2014, 02:36:39 PM
Knuckle #2 blasted and painted.

(http://i132.photobucket.com/albums/q17/wingman0/knuckle2.jpg)
Title: Re: Willys MB build
Post by: Wingman on October 04, 2014, 02:13:18 PM
Old F9 housing sold.

PSC steering parts arrived today.

(http://i132.photobucket.com/albums/q17/wingman0/Willyshydrosteering.jpg)
Title: Re: Willys MB build
Post by: Wingman on October 11, 2014, 09:13:42 AM
sMike welded on the inner Cs.  He's got far more talent than I.

Couldn't find room for upper link of 3-llink so single side Y-link fabbed.

(http://i132.photobucket.com/albums/q17/wingman0/WillysfrontYlink.jpg)

At full compression, track bar and upper link mount(s) tuck into frame rails and ahead of crank pulley.

(http://i132.photobucket.com/albums/q17/wingman0/Willystrackbar.jpg)
Title: Re: Willys MB build
Post by: Wingman on November 13, 2014, 05:20:19 PM
Steering ram mount done.

(http://i132.photobucket.com/albums/q17/wingman0/Willyssteeringrammount1-1.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/483b41ba-d022-4c2b-a3e9-b099b54ce176.jpg)
Title: Re: Willys MB build
Post by: Wingman on February 01, 2015, 09:51:00 AM
Finally got the "lead" out and got back into the shop.

Put together the front outer knuckle assemblies and mounted rollers.  Now sitting on all four.

Also reworked the Y-link because the original was not set properly.  This version cannot stay because it twists/pivots allowing caster change.  Once final ride height is set, I'll fab another fixed Y-link.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_1182.jpg)

Bender work is starting to make this look more like a shell of a Willys.  Unless you've done this type of work before, you cannot fathom how time consuming it is!

(http://i132.photobucket.com/albums/q17/wingman0/IMG_1192.jpg)
Title: Re: Willys MB build
Post by: Wingman on February 14, 2015, 09:51:11 PM
Now with matching sides

(http://i132.photobucket.com/albums/q17/wingman0/IMG_1204.jpg)

and a partial 3/16" firewall

(http://i132.photobucket.com/albums/q17/wingman0/IMG_1205.jpg)

and some floor structure

(http://i132.photobucket.com/albums/q17/wingman0/33722f98-1d78-4cb9-87c0-a12f93671407.jpg)
Title: Re: Willys MB build
Post by: ollllllo on February 26, 2015, 05:31:06 PM
Looking good Mark.
Title: Re: Willys MB build
Post by: Wingman on March 29, 2015, 04:03:59 PM
Been a while but things are getting done...

Rear receiver
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0081.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0082.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0084.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 29, 2015, 04:04:39 PM
Final-cut to the front frame rails.
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0092.jpg)

"D" ring brackets welded front, back, and inside
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0093.jpg)

Corner reinforcement
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0097.jpg)
Title: Re: Willys MB build
Post by: smichaelR22 on March 30, 2015, 01:15:42 PM
looks good!
Title: Re: Willys MB build
Post by: Wingman on May 11, 2015, 03:22:13 PM
One bead lock tire/wheel combo completed.  Used factory Ford 16x7 wheels and Total Metal Innovations Weld-on Bead Lock kit.  Powder coated wheel, painted ring.  Well used 345/75R16 BFG KM2.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0140.jpg)
Title: Re: Willys MB build
Post by: Wingman on May 12, 2015, 04:16:35 PM
24 hours later, it is still at pressure.

Last three completed today.
Title: Re: Willys MB build
Post by: Wingman on June 13, 2015, 03:18:31 PM
Needed some extra space for front air shock lateral travel.  Opted to notch frame.  Probably not the best solution but it should be fine.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0172.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0173.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0175.jpg)
Title: Re: Willys MB build
Post by: Wingman on June 23, 2015, 08:37:03 AM
Upper shock mount completed.  1/4" with 3/16" gussets.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0200.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0203.jpg)
Title: Re: Willys MB build
Post by: Wingman on June 27, 2015, 03:22:22 PM
Matching frame notch and shock mount completed on passenger side.
Title: Re: Willys MB build
Post by: Wingman on August 07, 2015, 07:43:03 AM
Blown apart for welding...

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0006.jpg)
Title: Re: Willys MB build
Post by: Wingman on October 14, 2015, 04:28:43 PM
Final assembly has begun.  I needed to get the pile of parts back into the shop to make winter storage room.

Engine got a hole drilled for the dip stick, oil pan installed.  Trans got the torque converter filled and installed and then mated to the engine.  Trans/t-case adapter kit assembled with reluctor ring, RTV, seals, and Loctite.  Then refitted the pair back into the chassis.

A little toaster oven baking made the reluctor ring slide on a bit farther
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0121.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0122.jpg)

Finally married for good
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0123.jpg)

...and back to this point
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0125.jpg)
Title: Re: Willys MB build
Post by: ollllllo on October 14, 2015, 06:11:37 PM
What's your plans for finish on the cage?
Powder coat or spray can?
Arie has some really nice product he used on his CJ cage. Can't remember what it was.

Sent from my SM-N910V using Tapatalk

Title: Re: Willys MB build
Post by: Wingman on October 14, 2015, 07:24:41 PM
Rattle can. It's going to see abuse anyway. That is the final color.
Title: Re: Willys MB build
Post by: ollllllo on October 16, 2015, 07:24:02 AM
Oh.
My bad.
I thought it was primer still.
I can dig it!

Sent from my SM-N910V using Tapatalk

Title: Re: Willys MB build
Post by: Wingman on October 22, 2015, 07:35:29 PM
Erik and I went through the D300 t-case last weekend and installed the TeraLow 4:1 kit and Novak HD super short rear output.  Got it installed in the chassis today.
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0126.jpg)

Wasn't really confident in the upper link mount on the rear axle so it got some bracing.
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0137.jpg)

While the welder was warm, installed the axle armor...
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0135.jpg)
Title: Re: Willys MB build
Post by: Wingman on October 31, 2015, 09:32:25 PM
Rear axle shock tabs welded and painted.  Housing swung back in place.  Rear links welded, painted, and reinstalled.
Title: Re: Willys MB build
Post by: Wingman on December 11, 2015, 08:59:33 AM
Plugging away on the front axle...

Shock mounts burned in
High steer arms drilled
Hydro steering links cut and heim bungs tacked
Ram ends fitted and secured w/Loctite
High steer arm spacers cut to fit
Diff armor welded in place
Inner axle seals installed
Prepped/painted bottom of housing
Steering links welded and prepped/painted
High steer arm spacers prepped/painted

.750 x .120 steering shaft tube obtained
Title: Re: Willys MB build
Post by: Wingman on December 11, 2015, 09:00:01 AM
Front axle 'finished' and back in place

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0187.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0188.jpg)
Title: Re: Willys MB build
Post by: Wingman on December 18, 2015, 11:25:55 AM
New Y-link made
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0190.jpg)

and now officially a 'roller'
Title: Re: Willys MB build
Post by: Wingman on December 20, 2015, 09:50:00 AM
exhaust work started

tight-radius turn downs cut and welded in
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0192.jpg)

rough placement over rear axle
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0193.jpg)
Title: Re: Willys MB build
Post by: Wingman on December 29, 2015, 05:06:09 PM
Radiator and grille mounting done

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0210.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0211.jpg)
Title: Re: Willys MB build
Post by: Wingman on December 31, 2015, 06:21:23 PM
Passenger exhaust tubing

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0212.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0213.jpg)
Title: Re: Willys MB build
Post by: Wingman on January 30, 2016, 08:56:05 PM
Been a while since last update.  Lots of stuff being tackled:

Brake booster rod fabbed and adjusted
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0240.jpg)

Brake pedal arm shortened and mounted
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0221.jpg)

Orbital mounted, steering shaft and u-joints fitted, tilt column and wheel mounted
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0227.jpg)

Exhaust finished except one band clamp, O2 sensors installed
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0243.jpg)
Title: Re: Willys MB build
Post by: Wingman on February 15, 2016, 08:21:44 AM
Front bumps done
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0248.jpg)

Front third member returned from ARB install
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0253.jpg)

...and front and rear third members set into the housings with LubeLockers
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0251.jpg)

All front heim bolts given a coating of anti-seize compound.
Axle housing breathers drilled and prepped.
Axle shafts ordered through ECGS.
Title: Re: Willys MB build
Post by: Wingman on February 27, 2016, 08:05:09 PM
This week's arrivals from ECGS
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0267.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0268.jpg)
Title: Re: Willys MB build
Post by: OffRad on February 28, 2016, 10:20:58 PM
awesome build. keep up the good work
Title: Re: Willys MB build
Post by: Wingman on March 05, 2016, 10:14:42 PM
Bulkhead done
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0120.jpg)

Floors and firewall done
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0122_1.jpg)
Title: Re: Willys MB build
Post by: s0l0ithz on March 12, 2016, 09:58:45 PM
Looking good ,shake down is just around the corner
Title: Re: Willys MB build
Post by: Wingman on March 13, 2016, 02:18:25 PM
Bed floor and sides done this week
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0130.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 13, 2016, 02:19:08 PM
Rolled it outside to blow off the dust and metal shavings and clean up the shop a little

Snapped a few teasers:
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0137_1.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0135_1.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0139.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0140_1.jpg)
Title: Re: Willys MB build
Post by: s0l0ithz on March 13, 2016, 10:26:01 PM
Does the Steering tilt in this thing?
Title: Re: Willys MB build
Post by: Wingman on March 14, 2016, 08:02:37 AM
Does the steering tilt in this thing?

Yes, tilt column and removable wheel.  ;D
Title: Re: Willys MB build
Post by: Wingman on March 21, 2016, 08:00:35 PM
Gussets and tabs
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0142.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0143.jpg)

Inner fender and side tins
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0161.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0165_1.jpg)
Title: Re: Willys MB build
Post by: OffRad on March 21, 2016, 09:32:37 PM
nice ride
Title: Re: Willys MB build
Post by: Wingman on March 23, 2016, 08:59:08 AM
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0166.jpg)
Title: Re: Willys MB build
Post by: s0l0ithz on March 24, 2016, 01:23:36 PM
Mark this is looking great
Title: Re: Willys MB build
Post by: Wingman on March 24, 2016, 09:29:45 PM
ECM returned after being reprogrammed by LT1swap.com

Fuel plumbing supplies ordered

Harnesses arrived too
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0172_1.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 02, 2016, 08:01:14 AM
one front fender completed
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0180.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0182.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0183.jpg)

rear axle shafts arrived today
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0181.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 05, 2016, 07:01:25 PM
Now with matching driver side.  It is officially a "flat fender" now.
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0187_1.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 08, 2016, 04:13:00 PM
Cowl done
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0190_1.jpg)

Time to move on to other little details
Title: Re: Willys MB build
Post by: Wingman on April 09, 2016, 06:14:06 PM
Rolled it out of the shop again to clean before beginning accel pedal modifications

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0193_1.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0195.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0194.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 11, 2016, 08:37:21 PM
Accel pedal mounted

Wiring harness pinout started
Title: Re: Willys MB build
Post by: Wingman on April 13, 2016, 08:14:27 PM
Doesn't this look FUN?!  Pin-out on the ECM...

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0200_1.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 20, 2016, 08:06:20 PM
Harness nearly done.  Relay pack needs to be assembled.
Title: Re: Willys MB build
Post by: Wingman on May 28, 2016, 06:31:33 PM
Installed the custom shafts in the rear housing.  It is officially a functional drive axle.

Running brake lines.  NiCu FTW!
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0254.jpg)
Title: Re: Willys MB build
Post by: Wingman on June 04, 2016, 07:13:46 PM
Front and rear lines run
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0258.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0256.jpg)
Title: Re: Willys MB build
Post by: Wingman on June 04, 2016, 07:14:03 PM
Front axle shafts assembled, short side installed.

Accessory bracket, alternator, and power steering pump installed.  Pulleys cleaned up.  Thermostat and new adjustable housing installed.

Fuse/relay block connected to the harness.  Power applied and pedal/throttle body and fuel pump feed tested good.
Title: Re: Willys MB build
Post by: Wingman on June 11, 2016, 09:39:42 AM
Arie sourced these awesome Cardone Ultra calipers.  Powder coated metallic silver, includes banjo bolt & crush washers, the works!  I'm impressed at the quality.
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0263.jpg)

Engine bay wiring nearly complete.  Used the old battery wiring harness for alternator and starter runs and put the battery terminal end to a junction block on the firewall.  Pulled switch panel power from there too.  Ran 1/0 from the junction block to the battery that will be located in the rear.
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0264.jpg)
Title: Re: Willys MB build
Post by: Wingman on June 12, 2016, 09:28:17 AM
Inner spindle/axle bearings replaced as a precaution.  Didn't want the 4340 stub shafts getting chewed up.  Front axle now an official drive axle too.

OEM battery ground cable cut and lugs soldered on for engine/frame grounding.
Title: Re: Willys MB build
Post by: Wingman on July 08, 2016, 09:58:33 AM
Catching up...

Driveshafts
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0269.jpg)

Coolers (steering on driver side, trans on passenger)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0271.jpg)

Temporary dash
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0275.jpg)

Belly skid plate
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0277.jpg)

Nitrogen or CO2 bottle mount
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0295.jpg)
Title: Re: Willys MB build
Post by: Wingman on July 11, 2016, 08:26:48 AM
Grand debut scheduled for FLX Club Picnic 7/23/2016 if you want to see this project in person.  ;D
Title: Re: Willys MB build
Post by: Wingman on July 20, 2016, 03:07:07 PM
Decided on a shifter thanks to BillaVista (http://www.billavista.com/tech/Articles/Ultimate_Offroad_Auto_Shifter/index.html)
and will modify the gates after more seat time
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0303.jpg)

Started tunnel so I could mount it
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0312.jpg)

Made a "keep-my-fingers-out-of-the-CV" cover
and welded in passenger harness mounts
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0314.jpg)

now officially a two seater with cup holders!
Title: Re: Willys MB build
Post by: Wingman on July 28, 2016, 12:16:50 PM
From Rausch Creek run July 4 weekend

(http://bb.m4wdfabrications.com/index.php?action=dlattach;topic=1291.0;attach=3157;image)
(http://bb.m4wdfabrications.com/index.php?action=dlattach;topic=1291.0;attach=3155;image)
Title: Re: Willys MB build
Post by: Wingman on August 09, 2016, 03:39:51 PM
Winch mounted and wired with 1/0 cable

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0317.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0318.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0327.jpg)
Title: Re: Willys MB build
Post by: Wingman on August 14, 2016, 04:38:18 PM
Got it weighed (half fuel, me in the seat)

Front: 1100#/1000#
Rear: 950#/900#

total: 3950#

Hit my target of <4000# with pretty good bias.  I'm pretty happy with that!
Title: Re: Willys MB build
Post by: Wingman on August 15, 2016, 05:06:31 PM
Heatsink cooler not pulling enough heat out of the trans on these hot humid days so it was time to get serious...

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0331.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0334.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0335.jpg)
Title: Re: Willys MB build
Post by: Wingman on August 15, 2016, 05:07:29 PM
Also added some high-performance items over the weekend  ;D

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0338.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0342.jpg)
Title: Re: Willys MB build
Post by: kensdodge on September 15, 2016, 04:26:55 AM
Damn that lil bugger is comin along pretty sweet man nice work
Title: Re: Willys MB build
Post by: Wingman on November 01, 2016, 09:25:25 PM
Finally got the second t-case shifter vetted and installed. Required a little trans pan trimming but not bad. It'll be nice to have HI range available. Also, low range front dig now possible.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0054.jpg)
Title: Re: Willys MB build
Post by: Wingman on November 01, 2016, 09:26:55 PM
While at Rausch Creek last weekend, the shift rail cap popped off and drained nearly all of my t-case on Shoot the Moon. I am now hypothesizing that it occurred because of hydraulic pressure. The caps fill with fluid and then when shifting, the fluid cannot exit the cap fast enough and it gets pushed out. While it may not pop off on the first shift, it likely loosened it to the point that another shift or hard bump may eject the cap. This wouldn't occur if the Dana 300 wasn't upside down because no fluid would settle or drain into the caps.

Here is my quick and dirty solution

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0055.jpg)
Title: Re: Willys MB build
Post by: Wingman on December 03, 2016, 05:32:15 PM
As noted in Trip Reports, the Willys made a trip to Utah in November and wheeled some iconic trails. It performed nearly flawlessly...

...except for some driver error  ;D
(http://i132.photobucket.com/albums/q17/wingman0/West%20Wheelin%202016/IMG_0300.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/West%20Wheelin%202016/IMG_0301.jpg)

The roll did tweak the radiator and A-pillar hoop. Some minor trail repairs in the form of upper radiator mount relocation kept it wheelin' for the remainder of the trip.

So, after a good season of working bugs out, it's time to do some repairs as well as finish work and improvements. Here's the beginning of the list:

trans tunnel
trans shifter mod
shock oil
front "suck down"
fuel cell with internal pump
fluid containment
dash
passenger "OH S**T" bar
LS6 intake
hood
tires
Title: Re: Willys MB build
Post by: Wingman on March 06, 2017, 10:24:56 AM
Catching up...

Used a porta-ram to un-tweak the radiator hoop and A-pillar hoop as much as I could from the rollover. Refabbed the radiator and grille mounts.

Added spreader bars
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0293.jpg)

Fuel cell (approx. 20 gals)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0298.jpg)

Internal baffling
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0297.jpg)

Pump retainer rings
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0299.jpg)

HF tread strips to space it up off the floor
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0322.jpg)

Final install except for bolts/nuts and vent tube
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0323.jpg)

Designed for GM truck fuel pump (built-in reservoir cup and
tip-over valve, part store availability, fuel gauge potential)
(http://images.wrenchead.com/smartpages/partinfo_resize/DRE/2630370-007.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 24, 2017, 06:37:56 PM
Upgrading my engine fuse/relay panel

Old DIY basic hack
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0341.jpg)

New unit with fan relays
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0336.jpg)

Also ripping into the harness to cull some unneeded
trans wiring and relocate ECM inside/under the cowl
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0343.jpg)
Title: Re: Willys MB build
Post by: Wingman on March 24, 2017, 06:45:27 PM
Engine harness finally complete.

ECM, TCM, and fuse/relay block mounted to cowl
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0357.jpg)
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0358.jpg)


Also got accessory drive ironed out in prep for LS6 intake

2010 Camaro water pump
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0346.jpg)

ICT Billet LS3 alternator mount
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0347.jpg)

2000 Camaro tensioner, custom bracket
(http://i132.photobucket.com/albums/q17/wingman0/IMG_0348.jpg)
Title: Re: Willys MB build
Post by: Wingman on April 14, 2017, 08:50:10 AM
New accessory drive routing is a failure.   >:(

Belt flaps badly between crank pulley and alternator under any current load. I can quiet it with added pressure on the tensioner but not adequately.

Attempt #2 = Goatbuilt low-pro alternator mount (https://goatbuilt.com/shop/products/gm-ls-passenger-side-alternatortensioner-bracket/) and tensioner, fixed the issue.

(https://goatbuilt.com/wp-content/uploads/4405-Side-View-500x500.png)
Title: Re: Willys MB build
Post by: Wingman on April 14, 2017, 08:51:18 AM
Cut some plywood to cover and insulate the floor and protect the fuel cell.
Also mounted the nitrogen bottle again.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0365.jpg)

Mounted a permanent first aid kit.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0370.jpg)

Harry found me a set of red label BFG Krawlers in Texas. Fastenal shipping FTW.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0367.jpg)

Mounted up on KMCs. Nice to have tread!
First time out of the shop since Nov.

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0385.jpg)
Title: Re: Willys MB build
Post by: Wingman on May 08, 2017, 05:30:03 PM
Even though it was raining at RC this past weekend, the improvements made over the winter performed as well as expected. The tires worked great.

Time to work on lighting.

Can't wait for the next trip! Field & Forest, look out!
Title: Re: Willys MB build
Post by: Wingman on May 26, 2017, 09:58:01 AM
Flawless performance at F&F this past weekend! That place is no joke...  8)

(http://i132.photobucket.com/albums/q17/wingman0/f831f13267cd8225242ad9da10a99788.jpg)
Photo courtesy of Hannah Szynal
Title: Re: Willys MB build
Post by: Wingman on June 21, 2017, 02:27:48 PM
Lighting finished up

(http://i132.photobucket.com/albums/q17/wingman0/IMG_0575.jpg)

Local inspection completed, two DMV trips and voila!

(http://i132.photobucket.com/albums/q17/wingman0/477f4ca2-d815-46e5-8a59-fca2c6ef550c.jpg)
Title: Re: Willys MB build
Post by: Wingman on July 18, 2017, 10:12:43 AM
Field & Forest trip 5/20/2017

https://youtu.be/HMS0KIA42rs
Title: Re: Willys MB build
Post by: Wingman on November 10, 2021, 07:30:12 AM
The Willys is getting some new reds this winter!
(https://uploads.tapatalk-cdn.com/20211110/73d8f5f5d17aeb3b75d0dfbaeeb81ec3.jpg)
Title: Re: Willys MB build
Post by: MrMindless on November 10, 2021, 09:01:22 AM
going to really be F&F ready!

If I start doing more fun runs I think I'm going to have to consider some of those...
Title: Re: Willys MB build
Post by: Wingman on March 14, 2022, 05:01:12 PM
Fired right up and pulled out of trailer storage. New tires mounted.(https://uploads.tapatalk-cdn.com/20220314/1c119721380da844445637b9d406626e.jpg)
Title: Re: Willys MB build
Post by: Wingman on October 27, 2022, 11:31:05 AM
Rear driveshaft mods by Loco
(https://uploads.tapatalk-cdn.com/20221027/10d3e99b8afdcf0f9faad57e5d8db40c.jpeg)
(https://uploads.tapatalk-cdn.com/20221027/9b8310af01d311f326899f518af2588c.jpeg)
(https://uploads.tapatalk-cdn.com/20221027/04513a029998ffc4f25ecb62f4898648.jpeg)
(https://uploads.tapatalk-cdn.com/20221027/cd5a404350c7102ba6226201f765f721.jpeg)
(https://uploads.tapatalk-cdn.com/20221027/91ffba003e8eba5430c10a8b174a5829.jpeg)

test block /modules/smf/index.php?action=printpage;topic=3415.0