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

Tweet

Great work as usual! An older friend of mine makes bed sides just like the way you are planning to. Great job on those exhaust hangers, thanks for sharing.

Originally Posted by 40FordDeluxe

Great work as usual! An older friend of mine makes bed sides just like the way you are planning to. Great job on those exhaust hangers, thanks for sharing.

Thanks Ryan, glad your enjoying it

.

It was like summer at the weekend so some progress was made, I ordered some tube for the bedsides and it arrived in time, I knew right from the start welding the tube to the top of the sides was gonna be a pain and also a 2 man job, so I got my mate Gary to help out, I like working with Gary as he knows what he's doing and dn't keep asking "why are you doing it that way "

First job was to get the tube tacked in place, it was cut longer than needed to allow for somewhere to clamp the ends. Welding 16swg sheet to 16swg tube is always a challenge as the tube tends to bow , Tig was out of the question due to the heat involved so we both decided to Mig and quench each weld as we danced around the joint.

We tacked it every 10" while checking with a straightedge first








Then clamped it to a piece of 2" x "2 box section, we were both convinced if we laid down 1/4" welds by dancing around in lots of different places and quenching with a damp cloth as quickly as possible every thing would be fine Here it is unclamped after cooling but when we checked it for straightness it had bowed very slightly , I can correct this with a touch of heat and a damp cloth later as it isn't too bad at all.








We decided on the other side to try and predict the bow by using a 1/4" packer in the centre and 1/8" outers and only clamp at the middle & ends, we used the same welding & quenching procedure, result was it came out perfectly straight when unclamped







Next job was to sand down the welds and metal finish it all.










Heres the bowed side and below the straight side










Here they are all metal finished and ready for the stake pockets to be welded on.










Next job was to mark out and drill the holes so the pockets could be plug welded in place










To protect in between the seams 3 coats of Epoxy primer were applied. then the pockets were clamped in place, and thats as far as it got until next time.







.

Nice work Steve. You always make it look easy. Thanks for the extra detail shots of the process.

Originally Posted by stovens

Nice work Steve. You always make it look easy. Thanks for the extra detail shots of the process.

Cheers Steve. If it was easy everybody would be doing it

.

Dragged my Mig welder out tonight, use it very rarely these days, everybody wants to see Tig these days, Anyway plug welded the stake bed pockets onto the sides and sanded down the welds, it will need a thin skim of filler (gasp shock horror !!!) to sort it out straight as the sheet pulled around slightly.
I also went and collected the front panel we bent up that I forgot the other day, thats the next job to sort.







.

Now I'm a bit confused, yeah, that was easy, I realize you build the coupe outside your home as you are with the pickup, so where is Sue's Roadster pickup while you are working in the garage ? And is Langys Hot Rod Shop at a different premises for the customer work you do ? What ever the situation is, you do absolutely brilliant work and I too appreciate you taking the time to photograph and explain to us how and why you do things. And now we know what pees you off in the workshop and we promise not to ask why, can we all be your helpers in the garage please.....

Originally Posted by Whiplash23T

Now I'm a bit confused, yeah, that was easy, I realize you build the coupe outside your home as you are with the pickup, so where is Sue's Roadster pickup while you are working in the garage ? And is Langys Hot Rod Shop at a different premises for the customer work you do ? What ever the situation is, you do absolutely brilliant work and I too appreciate you taking the time to photograph and explain to us how and why you do things. And now we know what pees you off in the workshop and we promise not to ask why, can we all be your helpers in the garage please.....

Whip we have a single car garage on the side of our house which houses Sue's Roadster pickup, my domain is the large workshop at the bottom of our garden, we are an end house so have a side access to the workshop.

.

Great work, what primer did you use? Is it brush on? Thanks for the great details here.

Originally Posted by 40FordDeluxe

Great work, what primer did you use? Is it brush on? Thanks for the great details here.

Ryan I just rollered on some epoxy primer to stop flash rusting from handling, it will get sanded and sprayed later.

.

Originally Posted by 40FordDeluxe

Great work, what primer did you use? Is it brush on? Thanks for the great details here.

Ryan I just rollered on some epoxy primer to stop flash rusting from handling, it will get sanded and sprayed later.

.

We like to use Por 15 for steel and rust issues, problem is it doesn't come off easy, and you definately want to have a top coat over the Por 15 while it's still a little tacky or nothing will stick to it! They actually now make a top coat for it. Can't beat it for rust and bondability!

Originally Posted by stovens

We like to use Por 15 for steel and rust issues, problem is it doesn't come off easy, and you definately want to have a top coat over the Por 15 while it's still a little tacky or nothing will stick to it! They actually now make a top coat for it. Can't beat it for rust and bondability!

Epoxy far exceeds the spec of Por15 Steve, its not porous and has anti corrosive qualities.

.

Picked up the front panel I had left at the machine shop and last night made a start on it, first job was to prepare the tube that gets welded to the top edge to be the roll, I like the idea of having a bolt each end on this to anchor it to the bed sides so first job was to cut the tube to length and turn up a couple of weld in bungs with threaded holes in them.








These were then welded into each end of the tube and the welds smoothed out.








Then the tube was tacked to the front bed panel the same way as we did the sides, this is where I realised I had my a slight error I had measured the tube but not allowed for the 2 thickness's of sheet either end so each end was slightly shy school boy error but thats what you get for rushing








I found an easy solution though, well 2 easy solutions, the first was to split the tube and extend with a piece of solid, the 2nd was easier so went with that, a standard washer was the same thickness as the sheet and with one side trimmed was a great fit








The washer was tig welded in place and sanded smooth, no one will ever know










The sides had to be drilled for the small bolts that hold the front panel to the sides, so measurements were taken and the sides drilled.








Today I took it all outside to see how it looked bolted together, looks pretty good to me








The open ended tubes on the sides were bugging me so I turned up some stainless bungs to cap them off, nothing fancy but practical.









.

Just been in catch up mode,Steve.. Haven't been in here for a while,,just a little look here and there.. This is looking awesome..Really nice work,as usual..Love your detail.. One kool pickup..