Moparts

Willys Wagon Build

Posted By: moparts

Willys Wagon Build - 08/01/11 03:33 PM

Lets start with , I have a 57 Willys wagon with a rusty frame,

So doing some looking around I figure that I should be able to mount the Willys wagon onto a CJ8 frame with out too much problem.

Using an after market ( stronger than stock ) CJ8 frame, And most of the parts from a CJ7 that I stripped, I should be able to complete this project with out excesses expense

Now the problem, with fuel prices going up, I want to get a good MPG with this rig.

First thought rebuilding the 4.2 6 cylinder and keeping the all jeep drive train, but thinking a diesel is the way to go.

Price on a 4BT is just too much, So thinking of tiring to fit a 6BT as in Dodge Truck Diesel into the CJ8 frame and boxing the firewall on the Willys Wagon.

Thoughts on this build or are there other diesel engines that I should be considering?
Posted By: moparmarks

Re: Jeep Build - For Off Roading and MPG - 08/01/11 04:46 PM

Doesn't the 6BT weight around 1000lbs? If so might want to think about beefing up that CJ8 suspension and brakes.
Otherwise you'd have one sick rig dude.
Posted By: Soopernaut

Re: Jeep Build - For Off Roading and MPG - 08/01/11 07:43 PM

There is a lot of good information here.

http://www.novak-adapt.com/knowledge/engines_general.htm
Posted By: ahy

Re: Jeep Build - For Off Roading and MPG - 08/02/11 01:41 AM

I know the 4.0 can be pretty thrifty when matched up to a manual transmission. My daughters '01 Cherokee gets 22 ish MPG cruising at 75 and isn't bad around town. The cam is small and the gears are long and it all works well together. If you want to run a carb I would guess its possible to convert. Plus the 4.0 is light, at least compared to a diesel which is an advantage off road and on. I've never done it but I understand the 4.0 head will fit a 4.2 which will give better breathing of the 4.0 plus extra torque.
Posted By: patrick

Re: Jeep Build - For Off Roading and MPG - 08/02/11 12:47 PM

I think I'd go in the archives and copy hotroddave's "super duper gas mileage 318" build and toss that in there...high compression, tight quench, very short solid cam and a t-quad...
Posted By: Cooter

Re: Jeep Build - For Off Roading and MPG - 08/02/11 08:46 PM

I really can't see the 6bt getting that much better fuel mileage than a 4.0. Plus, the weight, size, and limited powerband of the diesel will make this a very unwieldy project, to say the least. The scrambler frame, aftermarket or not, really isn't up to snuff for that much weight. Engine compartment size and radiator size will be two other limitations. If you are really set on doing this, I would suggest a Wagoneer frame. Or an Isuzu turbo diesel. Or both.
Posted By: Prince_Valiant

Re: Jeep Build - For Off Roading and MPG - 08/03/11 06:27 AM

it's not quite "mopar" but perhaps consider a Volkswagon 1.9 TDI?

There was someone who has swapped one into a later jeep with much sucess. Near 30mpg iirc.
Posted By: DaytonaTurbo

Re: Jeep Build - For Off Roading and MPG - 08/03/11 07:40 AM

http://www.jeepforum.com/forum/f12/3-0l-mercedes-turbo-diesel-into-1994-yj-835449/

This guy put an 80's mercedes 5cyl turbo diesel in his tj. Sounds like the hardest part was making the adapter plate to mate the motor to his ax-15 trans.
Posted By: DaytonaTurbo

Re: Jeep Build - For Off Roading and MPG - 08/03/11 07:42 AM

Quote:

I know the 4.0 can be pretty thrifty when matched up to a manual transmission.



You're the first person I've ever heard refer to the 4.0 as "thrifty"!
Posted By: RodStRace

Re: Jeep Build - For Off Roading and MPG - 08/03/11 04:53 PM

Hey we all want it all in our vehicles. The thought of a cheap trail rig thrown together and a 5.9 diesel just doesn't add up to me. Not unless you are climbing grippy terrian and hauling 4 tons!
Trails and MPG to me sounds like light and small. Something that can take an hour to go 2 miles and not make a dent in the fuel tank, and also doesn't require a mil-spec drivetrain.

How about outlining overall cost, type of trails and expected cargo and people loads?
Posted By: wimcle

Re: Jeep Build - For Off Roading and MPG - 08/03/11 08:29 PM

Don't forget that the jeep is less aerodynamic than a brick!

On the highway, there is a mpg limit you will hit no matter how efficient a motor you have.

On the trails, bouncing over rocks, creeping around in 2-lo, and etc. I find that I give out long before the gas tank does.

My opinion, pick a motor, then gear it to match. It's not going to make too much of a difference in the long run.

PS: Going down hill from vail pass, I have to give it gas to keep up to the speed limit, thats pathetic aerodynamics
Posted By: ahy

Re: Jeep Build - For Off Roading and MPG - 08/04/11 02:50 AM

Quote:

Quote:

I know the 4.0 can be pretty thrifty when matched up to a manual transmission.



You're the first person I've ever heard refer to the 4.0 as "thrifty"!



I'd go so far as to call it "perky" also! It just made a 2200 mile/2 1/2 day trip from Illinois to San Diego by the southern route loaded to the roof and pulling a trailer. Not one problem. Didn't even blow a trailer tire... probably because we had 2 spares.
Posted By: 360view

Re: Jeep Build - For Off Roading and MPG - 08/04/11 12:09 PM

The 1984 Lincoln Mk coupes had an option for a BMW built diesel.

http://carscoop.blogspot.com/2010/10/rare-find-1984-lincoln-continental-with.html

I had a mining engineer friend who had one in a Mark VII coupe and he got 32 to 34 MPG consistently on frequent trips from Whitesburg KY to Lexington KY

I did that same trip many times in a 1984 Ford Thunderbird gasoline V6 and typically got 24 MPG.
My brother had a 1986 Mercury Cougar turbo 4 and would get 26 MPG on the same exact trip.

It would be a relatively rare car to find in a salvage yard, but about the right size for Jeep duty.

The air cooled Deutz diesel used for portable pumps is a great design, and I have read where it has been retro-fitted into trucks.

If you wanted to stay with a newer design
consider the Motori diesel in the Jeep Liberty
or a VW TDI, including a 5 cyl TDI
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 08/07/11 10:43 PM

Tom ended up buying the PRICEY 4BT last night

He bought an entire Frito Lay truck

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Posted By: moparts

Re: Jeep Build - For Off Roading and MPG - 08/07/11 11:05 PM

Yes, just about to buy a wrecked Dodge 4X4 Diesel for the engine and trans.

But the 4bt in the bread truck showed up on Craigslist yesterday. Should have it on Monday Night

And the bread truck was cheaper also
Posted By: dynotune440

Re: Jeep Build - For Off Roading and MPG - 08/08/11 02:55 PM

you should make some money back scrappin the body
Posted By: MMiller

Re: Jeep Build - For Off Roading and MPG - 08/08/11 05:14 PM

I know that my 5.9 cummins in my 90, will go anywhere any of my other full size gasser friends trucks will go. It will wind in the mud with any bigblock for trail duty, and I can wheel a whole weekend on a few gallons of diesel. My buddy's with big blocks, and even small blocks, they are dumping gas in every night, sometimes even in the afternoon to finish the day.

After seeing mine work, and wheeling friend took his BBC out and will never go back. His tuned 5.9 cummins has never been a slouch to his BBC.

All that being said, I think a 5.9 is going to be a little much for the above said chassis. I think the 4 cylinder B will be sweet.

Michael
Posted By: moparts

Re: Jeep Build - For Off Roading and MPG - 08/08/11 10:40 PM

Quote:

you should make some money back scrappin the body



plasma cutter here go, scrap aluminum
Posted By: RodStRace

Re: Jeep Build - For Off Roading and MPG - 08/09/11 12:09 AM

Way to go, Tom!
That has got to be better than a 6 for your use.
Don't plasmacut, that's blowing money on the ground! Haul it down whole.
Heck, you could sell sheets as "Official Moparts Lightweight Patch Panels"...
At least cut out the signage and Ebay it as vintage and rare!
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 08/10/11 12:24 AM

Since Tom hasn't posted a pic of the Willys he bought off of me here you go....

Also, I decided to put a diesel in my Dodge M37 and suddenly he has to have one as well

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Posted By: Cooter

Re: Jeep Build - For Off Roading and MPG - 08/10/11 01:44 AM

Another nice rig. Makes me miss my M170, in a weird way.
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 09/03/11 05:34 PM

Now that the budget has increased for the Willys (Due to Tom owning it now....), I will be building it specifically for Peterson's 4Wheel & Offroad Ultimate Adventure 2013

Posted By: 76dodgeboy

Re: Jeep Build - For Off Roading and MPG - 09/03/11 05:57 PM

Quote:

Tom ended up buying the PRICEY 4BT last night

He bought an entire Frito Lay truck



Does the frito lay truck have 19.5 Single rims? If so Id be interested

I like these old willys
Posted By: GO_Fish

Re: Jeep Build - For Off Roading and MPG - 09/05/11 02:07 AM

Quote:

Since Tom hasn't posted a pic of the Willys he bought off of me here you go....

Also, I decided to put a diesel in my Dodge M37 and suddenly he has to have one as well



Gotta love those old Willys!

I saw an orange one about 10 years ago at Carlysle (sp), had a 350 bowtie and a lift kit. VERY Sweet truck, but i couldn't get past the Chevy power.
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 09/05/11 12:42 PM

Quote:

Quote:

Tom ended up buying the PRICEY 4BT last night

He bought an entire Frito Lay truck



Does the frito lay truck have 19.5 Single rims? If so Id be interested

I like these old willys



16", its on a 1977 P30 chassis
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 09/24/11 10:30 PM

I finished removing the 4BT from the Frito Lay truck while Tom removed the rest of the body. The motor is tiny once it is sitting all by itself. About the length of a 2.2L but taller. I will be swapping the drive assembly from one of my 6BT to give Tom a Chrysler alternator and an AC compressor. I will also be installing my vacuum pump onto his motor. (My deuce won't be needing a vacuum pump )

The 4BT is getting repainted the Cummins Beige that it already is. I will paint Tom's A518 trans and NP205 the same color as well.
Posted By: Defbob

Re: Willys Wagon Build - For Off Roading and MPG - 06/30/13 07:59 PM

I started on the frame for Tom's Wagon since my Dart is off at the bodyshop. It is made from 3x4" 3/16 wall tubing. I am stretching the wheelbase to 112". I have a set of Rubicon Express 1.5" SOA springs and leaf spring hardware from Ruff Stuff. The front D-ring shackles are from Ballistic Fabrication and were the only one long enough to fit through the 3" thick crossmember. The crossmember is the front bumper, that way nothing will be directly in front of the front tires.

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Posted By: Defbob

Re: Willys Wagon Build - For Off Roading and MPG - 06/30/13 08:00 PM

All tacked together.

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Posted By: Defbob

Re: Willys Wagon Build - For Off Roading and MPG - 06/30/13 08:00 PM

and square... I hope

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Posted By: Defbob

Re: Willys Wagon Build - For Off Roading and MPG - 06/30/13 08:02 PM

I will finish weld the connections next weekend and add some gussets to certain areas. Gonna be Ultimate Adventure strong

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Posted By: 76dodgeboy

Re: Jeep Build - For Off Roading and MPG - 07/01/13 12:55 AM

Quote:

Tom ended up buying the PRICEY 4BT last night

He bought an entire Frito Lay truck


What size Rims does it have and are the Super singles aka Non-dually
Posted By: 76dodgeboy

Re: Jeep Build - For Off Roading and MPG - 07/01/13 12:57 AM

I didnt see how old the post was
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/01/13 03:19 AM

It had dually wheels
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:29 AM

4BT is waiting for me to make the new water inlet/alternator/A/C bracket

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:30 AM

New TJ Wrangler Hellwig 1-1/4" swaybar

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:31 AM

Dodge Dana 60 front axle that I narrowed to 63.8" wide and fully rebuilt with locker waiting to go in.

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:32 AM

Houston, we have pintle

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:33 AM

Crosby shackles came in the other day

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:34 AM

attached to the Ballistic Fab weld-through d-ring mounts

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:35 AM

front frame step reinforcement

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:35 AM

rear frame step reinforcements

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:36 AM

springs mounts squared and tacked in place

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:37 AM

more squared

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:38 AM

more more more

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 12:38 AM



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Posted By: 76dodgeboy

Re: Jeep Build - For Off Roading and MPG - 07/22/13 04:42 AM

Quote:

Dodge Dana 60 front axle that I narrowed to 63.8" wide and fully rebuilt with locker waiting to go in.

Wher do you get your parts? Id like to do Crossover/high steer on my Powerwagons but dont want to break the bank
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/22/13 03:25 PM

Quote:

Quote:

Dodge Dana 60 front axle that I narrowed to 63.8" wide and fully rebuilt with locker waiting to go in.

Wher do you get your parts? Id like to do Crossover/high steer on my Powerwagons but dont want to break the bank



The high steer arms are from Ballistic Fab. They make the highest quality high steer arms.
Posted By: NoFrills

Re: Jeep Build - For Off Roading and MPG - 07/23/13 10:22 PM

This looks like its going to be a cool wagon when its done. I hope you have better luck with seletro hubs and a locker then I have. My ramcharger with a 60 in front broke 3 of them
Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/26/13 01:31 AM

I finished the reinforcements for the pintle hitch. I still have to make exterior ones to further strengthen the rear bumper.

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Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 07/26/13 01:34 AM

Some spray lube had gotten onto the front bumper around the front hanger, I have to do some cleaning before I can finish welding them

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:18 PM

For the skid plate mount, I duplicated the factory mounts of a TJ Wrangler

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:19 PM

And skid plate mounts welded

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:28 PM

I then flipped the frame over and mounted the springs and axles so that I could verify my calculations on the position of the steering box.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:30 PM

Steering box location is perfect , tie rod will not rub against the draglink and managed to keep minimum front overhang

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:35 PM

I mounted the box low as so it will not interfere with the winch plate

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:37 PM

The box is also level and not angled like the factory has them mounted, this may alter the effective ratio

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:38 PM

The beastly pitman arm is from Sam's Offroad

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:44 PM

Beauteous Dana Sixeous

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/03/13 11:46 PM

...And introducing in the other corner, weighing in at over 500lbs..... Corporate... 14 Bolt!

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Posted By: dynotune440

Re: "TastyKake" - Willys Wagon Build - 08/04/13 03:54 PM

its lookin good!
Posted By: Geezer

Re: "TastyKake" - Willys Wagon Build - 08/04/13 04:10 PM

Any bracing or support planned for the steering box?From the pictures provided it looks like with serious off-road use it will end up flapping in the wind. http://www.polyperformance.com/shop/Syne...00-p-29632.html
Posted By: Rug_Trucker

Re: Jeep Build - For Off Roading and MPG - 08/04/13 04:14 PM

Posted By: Defbob

Re: Jeep Build - For Off Roading and MPG - 08/04/13 05:22 PM

It's not finished yet, I just wanted to get it in position. I will build a box to house the tubes for the lower mounts.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/04/13 09:47 PM

Fuel tank is mounted.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/04/13 09:48 PM

The fuel tank is a CJ7 15 gallon poly tank, I will be switching it to a Pre-'80 tank in order to get the larger inlet which will be needed for the output of the diesel pumps.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/04/13 09:50 PM

The skid plate is from Max-Bilt, I actually mounted it backwards so that the high bolts are in the rear.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/04/13 10:03 PM

I still need to do some finish welding on the bottom, but that will wait until I have all of the stuff mounted from the top that required the axles to be in place for mock up.

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Posted By: Twostick

Re: "TastyKake" - Willys Wagon Build - 08/09/13 01:05 AM

That should do 30+ mpg especially if you put on an air to air aftercooler and gear it accordingly.

Kevin
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/18/13 06:18 PM

It will have a small intercooler in front of the radiator and the axles have 4.10 gears with 37" tires, plus the tranny has overdrive.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/18/13 07:39 PM

I finished boxing the step in the frame... it won't be flexing here

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/18/13 07:40 PM

"A smart fellow could put his knee up on such a step."

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/18/13 07:41 PM

Shock towers came in from RuffStuff. I will hold off on welding them on until after the body is on and the nose is positioned.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/18/13 07:42 PM

I finished making the outside rear bumper reinforcements, I had to keep them a little narrow to fit within the qtr panels

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/18/13 07:43 PM

I also made the rear shock crossmember

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Posted By: all spooled up

Re: "TastyKake" - Willys Wagon Build - 08/18/13 11:59 PM

that is some nice fab work
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/19/13 11:18 AM

Thank you
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/24/13 06:31 PM

Fabricating the lower steering box mounts

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/24/13 06:32 PM

And some plate to make it purdy

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/24/13 10:21 PM

and welded

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/24/13 10:23 PM

Frame is now upright and ready to start assembling and painting as I go (with brush on paint)

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 08/24/13 10:24 PM

You can never have too big of a d-ring...

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Posted By: Golden-Arm

Re: "TastyKake" - Willys Wagon Build - 08/26/13 09:04 PM

the d-rings should be sturdy enough to be able to lift the truck off the ground, using them.

awesome looking work. waiting to see whats next.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/08/13 08:37 PM

body off the old frame

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/08/13 08:38 PM

Some wrecker drivers saw I was in need of a hand and stopped to help

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/08/13 08:38 PM

Body plus new frame

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/08/13 08:39 PM

just looks so bad

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/12/13 11:41 AM

All 4 tires are on the wagon now

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/12/13 11:43 AM

I will have to remove the tubs and make new ones for the slightly altered wheelbase.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/14/13 10:32 PM

Front frame horns are done. I need to grind off the lower weld and redo it, the trigger was messing up and an caused erratic bead.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/14/13 10:35 PM

driver side frame horn.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 09/14/13 10:35 PM

back view of frame horn.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/06/13 02:16 PM

I needed to get some more weight in the chassis before continuing with some more items. So I started making the motor mounts.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/06/13 02:17 PM

I figured if leaf spring bushings can withstand offroading, they can tolerate a little 4BT

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/06/13 02:18 PM

This is how the motor looks in place

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/06/13 02:19 PM

Lots of oil pan clearance

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/06/13 02:21 PM

skid plate assembly will hang about 6" below the frame rail to clear the transfercase

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/06/13 02:22 PM

Now that the motor mounts are made, I was able to make the tranny mount which will be separate from the skid assembly. I had to make it swoop down in order to clear the driveshaft at full droop.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/13/13 05:51 PM

Seats came in from Corbeau. They are heated Baja RS suspension seats.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/13/13 05:53 PM

Intercooler came in as well. I got one that will be small enough to fit inside the grille.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/13/13 05:54 PM

I also got the rock sliders welded on. The whole exo-cage and front fenders will be based off of them.

Attached picture 7886081-10-13-13-01.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/13/13 05:56 PM

The front swaybar frame mounts are made and the shock passenger shock tower is tack'd in place to check clearance.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 10/13/13 05:57 PM

nice clearance with the grille

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Posted By: all spooled up

Re: "TastyKake" - Willys Wagon Build - 11/10/13 01:01 AM

looking good get any more work done
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 11/10/13 02:52 AM

I haven't done too much, been distracted. I removed the old wheel wells in the back in prep for new longer ones and made some more body mounts. I also mounted the Mustang hydroboost and made a huge notch in the tranny tunnel for the fuel pedal to be mounted near the center of the vehicle . The column shift steering column arrived as well as the dimple die for making steps out of the rock sliders. I'll take some picture tomorrow.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 11/30/13 11:38 PM

I started making the tube fenders

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 11/30/13 11:39 PM

I still need to notch the ends

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Posted By: roadrunninMark

Re: "TastyKake" - Willys Wagon Build - 12/06/13 07:01 PM

Incredible build! Does the 518 bolt up to the 4BT without any mods or what did you need to make it work?
Posted By: Guitar Jones

Re: "TastyKake" - Willys Wagon Build - 12/06/13 07:37 PM

Really looks good. It looks like though you could have stretched the front sheet metal and put a 5.0 V10 twin turbo VW TDI in there.
Posted By: moparts

Re: "TastyKake" - Willys Wagon Build - 12/06/13 10:54 PM

Quote:

Incredible build! Does the 518 bolt up to the 4BT without any mods or what did you need to make it work?



The back of the 4BT is the same as a 6BT ( Cummins ) so I used the adapter and trans from a 92 Dodge Cummins. Same starter also and the belt drive from the front of the Dodge.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 12/06/13 11:27 PM

I forgot to post the pictures of the fender tubes after they had been fitted and notched

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 12/06/13 11:28 PM

I still have to duplicate this to the other side

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Posted By: DusterDave

Re: "TastyKake" - Willys Wagon Build - 12/07/13 12:13 AM

Very nice work so far!
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 12/07/13 02:29 AM

I couldn't allow Tom to get stuck in Alaska or any place, so...

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 12/07/13 02:30 AM

Quote:

Very nice work so far!



Thank you Dave
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 12/08/13 03:08 AM

Mirror Mirror on the wall, make me a matching fender for the other side

Attached picture 7950991-12-7-13-01.jpg
Posted By: Fat_Mike

Re: "TastyKake" - Willys Wagon Build - 12/09/13 04:33 PM

Quote:

Mirror Mirror on the wall...



I gotta get one of those...

That's an awesome project. Thanks for taking the time to post your progress.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 12/16/13 12:44 AM

The Willys doesn't look so out of proportion now with the new fenders.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 12/16/13 12:45 AM

Fenders are welded on

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 01/11/14 11:10 PM

I mounted the steering column, nice and centered with the seat. I hate offset steering wheels (Cavaliers, etc...)

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 01/11/14 11:11 PM

Test fitting the billet a/c bracket

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 01/11/14 11:12 PM

Swaybar links are now the correct length I have tractor pins for disconnects, give you a nice handle to push and pull with.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 01/11/14 11:13 PM

Intercooler mounting has been figured out.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 01/11/14 11:14 PM

I was able to fit an 8" fan in front of the intercooler for when offroading.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 01/21/14 02:01 PM

Intercooler is mounted and so are the radiator and a/c condenser.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 01/21/14 02:01 PM

A/c compressor is mounted as well

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/06/14 12:12 AM

The inner tube of the fender is now in place

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/06/14 12:12 AM

The air compressor now has a home

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/06/14 12:13 AM

Battery box is mounted

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/06/14 12:14 AM

Steering shaft is now made with the Flaming River pinch joints

Attached picture 8028107-1-2-14-04.jpg
Posted By: DusterDave

Re: "TastyKake" - Willys Wagon Build - 02/06/14 03:24 AM

Quote:

Battery box is mounted


What group size battery do you plan to run? 34/78?
Posted By: moparts

Re: "TastyKake" - Willys Wagon Build - 02/06/14 10:51 PM

Quote:

Quote:

Battery box is mounted


What group size battery do you plan to run? 34/78?



Yes Have an Odyssey 34/78 Battery for it
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/08/14 11:56 PM

Started the winch plate today.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/08/14 11:57 PM

access for the steering hoses

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/08/14 11:58 PM

Finished the winch plate today.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/09/14 12:01 AM

Tom is going to borrow my 17,500lb winch until he gets a Warn Zeon 10K

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/23/14 07:10 PM

I made some progress on the cage

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/23/14 07:11 PM

after a few ideas, I settled on a place to attach the front hoop.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/23/14 07:12 PM

I also made a new main hoop that fit the body better

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 02/23/14 07:13 PM

The cage is starting to take shape

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/02/14 08:39 PM

TastyKake got some skin on its right front fender

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/02/14 08:45 PM

exhaust is made, just waiting for the parts to make the hangers.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/02/14 08:47 PM

I made the down pipe from two 3" elbows and used a Dodge Cummins heat shield. It has V-bands at each end.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/02/14 08:48 PM

The ehaust pipe is protected by the rock sliders. I have much experience in crushing exhaust on rocks

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/02/14 08:50 PM

Out back is a Summit welded turbo muffler. It is almost a straight through design. I am curious how it will sound. It came painted a primer-grey color. It will be protected by the tire. I will most likely lengthen the rear pipe to have it exit closer to the rear of the wagon.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/02/14 08:51 PM

There is more than enough room for suspension flex without the tire contacting the muffler.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/05/14 06:25 PM

Tom's Warn Zeon 10S winch arrived Monday. I'll let him open it. I told him I am going to rebadge the winch, Warren Zevon.
Posted By: Jwilli500

Re: "TastyKake" - Willys Wagon Build - 03/06/14 08:10 PM

Quote:

Tom's Warn Zeon 10S winch arrived Monday. I'll let him open it. I told him I am going to rebadge the winch, Warren Zevon.



Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/12/14 01:41 PM

I need to post some pictures when I get home, I started skinning the front fenders and I made a box around the exhaust downpipe.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/12/14 11:00 PM

I still have to finish welding the skin on and make the removable access panels.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/12/14 11:02 PM

Moose-Proof

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/12/14 11:06 PM

The box to cover the exhaust downpipe

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/12/14 11:07 PM

The box all welded in

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/12/14 11:08 PM

And introducing Warren Zevon

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/16/14 02:41 AM

I made the removable side panels of the fenders today.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/16/14 02:42 AM

Trick tabs with 1/4 nuts are welded to the tubing.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/16/14 02:42 AM

Driver's side

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/16/14 09:55 PM

First coat of white Zero-Rust is applied to the fenders

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/16/14 09:56 PM

Looks like a real fender

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/16/14 09:57 PM

There are also rock light mounts on the underside.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/16/14 09:58 PM

I am happy with how the fenders turned out

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/16/14 09:59 PM

And the driver's side

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/23/14 02:56 PM

Intercooler tubes are finished and installed

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/23/14 02:57 PM

The intake side

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 03/23/14 02:58 PM

Winch is installed

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 04/20/14 12:52 AM

Tom has been making some headway with the wiring while I have been making progress on the cage.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 04/20/14 12:53 AM

front side of the cage

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 04/20/14 12:54 AM

I managed to get some more side bars in before calling it a day. Tomorrow I will make the roof bars.

BTW, Tom says hi

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Posted By: Golden-Arm

Re: "TastyKake" - Willys Wagon Build - 04/20/14 02:43 AM

looking good! are you sure tom is using all 5 fingers, waving at me?
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 04/20/14 03:40 AM

I am not authorized to release that information.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 04/21/14 03:48 AM

I only got a few bars done today. I made the rear bars between the windows

Attached picture 8119352-4-20-14-01.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 04/21/14 03:49 AM

and the two front roof bars. I only have the rear roof x to make before I pull the cage off to finish welding it and then do gussets.

Attached picture 8119354-4-20-14-02.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/03/14 11:25 PM

I pulled the cage off today so I could weld the underside. While I had it on the floor I made the roof rack for luggage when going on road trips.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/03/14 11:26 PM

I used 3/4" 13ga. expanded sheet

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/03/14 11:27 PM

with 1" angle iron along the sides for support and ratchet strap attachment points made out of 3/8" bar

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/03/14 11:29 PM

I also made a gusset for between the two bars that come up from between the rear windows

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/06/14 11:56 PM

Painted the underside of the cage before putting it back on the Wagon

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/07/14 12:02 AM

Cage was reinstalled and welded on for the final time. Gussets were also welded on

Attached picture 8136284-5-4-14-01.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/07/14 12:02 AM

I also made the hinges for the tire carrier

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/07/14 12:03 AM

The white cage helps hide it against the white body

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/13/14 01:56 AM

Side steps are made and welded on.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/13/14 01:57 AM

I got a 1/2" dimple die from TMR Customs

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/13/14 01:57 AM

I also made the rear wheel tubs today

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/13/14 01:58 AM

It is nice having a metal brake

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/15/14 12:10 AM

I started making the tire carrier today

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/15/14 12:11 AM

I am debating if I will add more bars to the main structure or just gussets

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/15/14 12:12 AM

Side steps are painted

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/15/14 12:14 AM

I finished and painted the box around the shifter. I also made the top removable.

Attached picture 8144772-5-14-14-05.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/16/14 11:41 PM

I have two plugs to weld in on the tire carrier and it can get painted.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/16/14 11:42 PM

The skull is getting painted white with red eyes

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/16/14 11:43 PM

License plate swings out with the tire carrier while the light stays on the body

Attached picture 8146688-5-16-14-04.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/16/14 11:44 PM

Just a random picture of the finished dash

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/16/14 11:45 PM

straight on from the dash

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/16/14 11:46 PM

lid for the shifter, boot is on order

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/18/14 12:54 AM

Tom bed lined the floor of his Wagon today and painted the tire carrier

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/18/14 12:56 AM

Then we installed the tailgate

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/18/14 12:56 AM

gate closed

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/18/14 12:58 AM

150lb tire mounted

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Posted By: Joshs68

Re: "TastyKake" - Willys Wagon Build - 05/18/14 04:52 PM

Very cool build.
Posted By: moparts

Re: "TastyKake" - Willys Wagon Build - 05/19/14 02:24 AM

Decided that it was time to fire this engine up for the first time

Did a check over and hit the starter and instant to life

Sounded good and remembered how much diesels vibrate

http://youtu.be/ahCPJhDS7BY

Attached picture 8148527-WillysWagon.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/26/14 02:57 AM

driveshafts came in

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/26/14 02:58 AM

Started on the skid plates

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/26/14 02:59 AM

And installed the driveshafts

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/26/14 03:00 AM

The rear driveshaft has to be shortened about 1.5"

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/28/14 10:35 PM

doors are finished, I welded on a threaded plate for the 03-06 TJ Wrangler mirrors. I also did a quickie patch on the lower 1/3 of the doors with some replacement panels.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/28/14 10:36 PM

I had to mount the mirrors back far enough to clear the vent windows.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/31/14 07:15 PM

Tailpipe is made, still have to do the hangers though

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 05/31/14 07:16 PM

The Mustang master cylinder is too small for the 1-ton brakes, so I installed a GM K3500 truck unit this morning.

Attached picture 8160896-5-31-14-09.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/03/14 10:39 PM

Transfer case skid is painted and installed

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/03/14 10:47 PM

Seat belts are installed, pinion angle set and perches welded, brakes are bled, alignment is done, and Tom drove it around the yard under its own power for the first time since he has owned it!!

Attached picture 8164512-6-1-14-07.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/09/14 11:21 PM

Tranny pan skid is done

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/09/14 11:23 PM

I finished the Wagon. Shocks are behind schedule, but Tom knows how to install those .

Off for a VIN check tomorrow for registration.

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Posted By: 11secdart

Re: "TastyKake" - Willys Wagon Build - 06/11/14 12:26 AM

What a beast!!! Cool!!!

Attached picture 8172071-IMG_0235.JPG
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/11/14 01:20 AM

Quote:

What a beast!!! Cool!!!



Thank you, and now it is registered as well
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/12/14 03:15 PM

http://youtu.be/F_46WjpA2ak

I drove the Wagon to work today as well
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/15/14 06:54 PM

Tom and I took the Wagon out for some light wheeling. Our friends Jim and George joined us in their Land Rover Defender.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/15/14 06:59 PM

We found out the Wagon is so heavy that it has trouble on steep hills even in 4lo. AND that a super heavy rig is too much for the Selectros. I had been warned but was determined to try them since my axle (originally built for my M37) has a mechanical locker up front. Tom blew it up real fast on a small ditch...

Attached picture 8176958-6-14-14-04.jpg
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/15/14 07:00 PM

Came off in sections...

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/15/14 07:02 PM

So I gave Tom my solid hubs. Now I am down more parts for my vehicles We drove the truck to see how it handled the locker. To my surprise it drove like an open diff. So the solid hubs and mechanical locker are staying

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Posted By: NoFrills

Re: "TastyKake" - Willys Wagon Build - 06/15/14 11:49 PM

After blowing up my selecros I also just use the stock drive flanges. For driveing down the road I have a set of aluminum bicknel flanges of a dirt track car with the splines boared out to keep the dirt out. When I get where im going I just take out the bolts and swap them out. If you change the hub out to the 91-93 dodge style they are the same as a chevy and there are alot more options of locking hubs.

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Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/16/14 02:27 AM

Tom has a set off of his '92 axle, but he sold the Warn selectors. I had gotten him a set of Solid 35spline slugs for them, because he was suppose to get an ARB.
Posted By: moparts

Re: "TastyKake" - Willys Wagon Build - 06/18/14 12:24 AM

Messed with the injection pump and went from "Slow under powered" to wow it goes now.

Turned the power screw in two turns from stock. It still had the collar on it so it had never been messed with.

Joy to drive now, get up and goes, just a little gray haze in the exhaust on first take off.

http://youtu.be/q7qAp2YDHig

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Posted By: Golden-Arm

Re: "TastyKake" - Willys Wagon Build - 06/18/14 06:28 AM

the pic with the defender looks like you guys are on an old railroad roadbed.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/19/14 02:54 AM

It is a local dam on the Shetucket river.
Posted By: Golden-Arm

Re: "TastyKake" - Willys Wagon Build - 06/19/14 06:50 AM

cool. nice to see you getting finished up.
Posted By: Defbob

Re: "TastyKake" - Willys Wagon Build - 06/23/14 12:53 PM

The real shocks have shown up

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Posted By: moparts

Re: Willys Wagon Build - 08/12/14 01:18 AM

This weekend

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