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

Cleared my car out today and nearly forgot about this little gem I picked up yesterday, I like alternators but not on vintage engines so I picked this up off my friend Ian, (thanks Ian) Its an alternator in a Generator casing, So you get a good reliable output with old looks. :cool:

I looked through my scrap aluminium bin but nothing the right size for the double vee belt pulleys so popped into the metal stockists today and picked up some bar offcuts for beer money What you see here will become the 2 x 6" main pulleys, a 4" idler pulley and a 4" steel crank hub, Looks like I will be making a lot of swarf tonight !!! :LOL:



http://i65.photobucket.com/albums/h2...psm4o80pcw.jpg

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Very cool! Reading your post brought a big smile of wonder to my face. Continually amazed with your eye for detail and abilities to scratch build items needed! Gotta shop for a lathe before I'm too old to use it!

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Originally Posted by rspears

Very cool! Reading your post brought a big smile of wonder to my face. Continually amazed with your eye for detail and abilities to scratch build items needed! Gotta shop for a lathe before I'm too old to use it!

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Yeah you need a lathe in your life mate :LOL:

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Spent the last couple of evenings leaning over the lathe, got backache now !!! Anyway underneath the huge clumps of swarf these appeared

These are the idler components, I took a pic of the bearing number which might be handy for someone ding similar, dims are 52mmOD. 25mmID, 15mm wide



http://i65.photobucket.com/albums/h2...psekuhuwma.jpg

http://i65.photobucket.com/albums/h2...ps2yupgrpd.jpg


Assembled



http://i65.photobucket.com/albums/h2...psoncmv3np.jpg

http://i65.photobucket.com/albums/h2...psgxxnsjj8.jpg




Here's the complete set, they are to work with 1/2" wide belts



http://i65.photobucket.com/albums/h2...psf8zpn933.jpg

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Very nice!You are a talented Gentleman!

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Originally Posted by roadster32

These are the idler components, I took a pic of the bearing number which might be handy for someone ding similar, dims are 52mmOD. 25mmID, 15mm wide

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What are these mm things you speak of? :LOL: :LOL: :LOL: ;)

Very nice work, by the way!

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Originally Posted by stovens

Very nice!You are a talented Gentleman!

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Gentleman might be taking it a bit far Steve :LOL:

Did you need dual belts??????????? finding matched length belts for proper tension is difficult and these days since production cars use serpinteen belts is going to be almost impossible------- but nice machine work

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Originally Posted by jerry clayton

Did you need dual belts??????????? finding matched length belts for proper tension is difficult and these days since production cars use serpinteen belts is going to be almost impossible------- but nice machine work

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You may of missed the reason why Jerry but I wanted an old Crager look so yes dual vee belts is what I wanted, personally I don't see a problem picking up vee belts as there are scores of places that sell them.
Lots of the guys are running dual belt drives without any problems.

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Quote:

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Originally Posted by roadster32

You may of missed the reason why Jerry but I wanted an old Crager look so yes dual vee belts is what I wanted, personally I don't see a problem picking up vee belts as there are scores of places that sell them.
Lots of the guys are running dual belt drives without any problems.

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I don't think you'll have any problem, Steve. Many, many industrial machines run multiple v-belts, and manufacturing tolerances have actually improved a lot over the years with the major suppliers. For example, Gates changed their manufacturing process almost 35 years ago to make their V80 series belts meet or exceed the specified tolerances for "matched set" belts, but if one is worried about it they can still be special ordered as "Matched Set Belts". If you want to go with a better quality, like a belt with aramid tensile cords that stretch very little, they require a match tolerance that is tighter than the RMA standard. Even then, V-belts with aramid cords (such as the Gates Predator) are matched by selecting belts with a single punch code. I'd say you're good to go, and beautiful work, as usual!

Can I bother you with a lathe question? You told me once before, but I think it was in a PM that was long ago deleted :o:( and with CRS I don't trust memory;). What's the minimum spindle bore that you recommend for a general purpose machine, and can you explain your reasoning? Sorry to be a bother, and I swear that I'll commit it to memory this time.... :rolleyes::LOL::LOL::LOL:

Roger-lathe info---------get one with spindle bore big enough that you can use a 5c collect set thru it--------
Mine is a Pratt & Whitney off a early 40s battleship------


And thanks for update on v belts

Quote:

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Originally Posted by rspears

I don't think you'll have any problem, Steve. Many, many industrial machines run multiple v-belts, and manufacturing tolerances have actually improved a lot over the years with the major suppliers. For example, Gates changed their manufacturing process almost 35 years ago to make their V80 series belts meet or exceed the specified tolerances for "matched set" belts, but if one is worried about it they can still be special ordered as "Matched Set Belts". If you want to go with a better quality, like a belt with aramid tensile cords that stretch very little, they require a match tolerance that is tighter than the RMA standard. Even then, V-belts with aramid cords (such as the Gates Predator) are matched by selecting belts with a single punch code. I'd say you're good to go, and beautiful work, as usual!

Can I bother you with a lathe question? You told me once before, but I think it was in a PM that was long ago deleted :o:( and with CRS I don't trust memory;). What's the minimum spindle bore that you recommend for a general purpose machine, and can you explain your reasoning? Sorry to be a bother, and I swear that I'll commit it to memory this time.... :rolleyes::LOL::LOL::LOL:

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I would look for the biggest spindle bore you can find Roger, mine is 1.75" which is a good size but still can't get 2" bar in
I wasn't worried about the belts to be honest as already sorted them out with my local bearing specialist.

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Started making the blower crank hub last night, another evening on the lathe, I chose to use a bit of 4" OD EN40 steel bar, tough to turn but ideal for the job.



http://i65.photobucket.com/albums/h2...psucgkujck.jpg



After a few hours I had this, Its a little long at the moment as I need to hold it to broach the double keyway, will trim to length once thats done.



http://i65.photobucket.com/albums/h2...psl5ugijhx.jpg

http://i65.photobucket.com/albums/h2...psidbqkfjg.jpg




Drilled the 6 bolt pcd into the pulleys



http://i65.photobucket.com/albums/h2...psrtm5vqiz.jpg




I got the various parts back from vapor blasting so nice and clean now.



http://i65.photobucket.com/albums/h2...pszftpdw0m.jpg

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http://i65.photobucket.com/albums/h2...psfufzqjwb.jpg




Stripped the blower down to get it all clean and fit new bearings and do the required modifications, during stripping everything was centre dotted to aid in reassembly to keep everything in sync.



http://i65.photobucket.com/albums/h2...psrijw4ibu.jpg




Undoing the gear bolts was a task as this blower has never been apart before, a bit of softwood jammed in the rotors stops any damage.



http://i65.photobucket.com/albums/h2...psj4hrx2fj.jpg




As the gears are helical they have to be pulled off together, a bit of scrap aluminium and some bolts were used as a simple puller.



http://i65.photobucket.com/albums/h2...psichmcupv.jpg




Again the gears were centre dotted to aid reassembly.



http://i65.photobucket.com/albums/h2...pska8lufjp.jpg

http://i65.photobucket.com/albums/h2...ps6kwu4t5i.jpg




Heres the empty case ready for vapour blasting.



http://i65.photobucket.com/albums/h2...psp2s4xvhb.jpg




These holes in the case both ends have to be tapped 3/8"NPT and filled with pipe plugs to stop oil.



http://i65.photobucket.com/albums/h2...psapjxzete.jpg

http://i65.photobucket.com/albums/h2...psnedky9iu.jpg

http://i65.photobucket.com/albums/h2...pstynazzx3.jpg

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Quote:

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Originally Posted by roadster32

I would look for the biggest spindle bore you can find Roger, mine is 1.75" which is a good size but still can't get 2" bar in
I wasn't worried about the belts to be honest as already sorted them out with my local bearing specialist.

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Thanks, Steve, on the lathe info. Yeah, the belt thing used to be a real problem back in the '60's & '70's, but since around 1980 became all but a non issue with mandatory tolerances and improved processes.

First of all, I really like your bracket/tab/fab design and work. my hat is off to you sir. Secondly, that blower was a great score, and will be an awesome added bonus on here! It's even better your mate had the front cover and a drive snout. The snout and drive parts bring more than a blower core up here. Way nice work on your pullies and idler. Nice markings before tear down to save you some head aches. The blower case looks pretty nice compared to some I've seen of that size. Great work, keep at it.

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Originally Posted by 40FordDeluxe

First of all, I really like your bracket/tab/fab design and work. my hat is off to you sir. Secondly, that blower was a great score, and will be an awesome added bonus on here! It's even better your mate had the front cover and a drive snout. The snout and drive parts bring more than a blower core up here. Way nice work on your pullies and idler. Nice markings before tear down to save you some head aches. The blower case looks pretty nice compared to some I've seen of that size. Great work, keep at it.

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Cheers Ryan, I'm pretty sure the blower has never been apart as there are no centre dots anywhere, yes it's in pretty tidy condition.

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Started making the blower snout shaft last night, used the EN40 offcut from the crank hub, drilled the mounting holes, next I need to make the drive shaft which will be welded and pinned to the hub you see here.



http://i65.photobucket.com/albums/h2...psxddhwrlz.jpg

http://i65.photobucket.com/albums/h2...pshwdek5ci.jpg

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Very nice, and those ARP fasteners finish it off. Do you buy those by the bag? I notice you use them a lot.

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Originally Posted by 40FordDeluxe

Very nice, and those ARP fasteners finish it off. Do you buy those by the bag? I notice you use them a lot.

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I'm a dealer for ARP Ryan so have them on the shelf, the best bolts around in my opinion, I only used the stainless as I didn't have any regular type, they will get changed.

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Came to a full stop on the snout shaft as run out of 1" bar so turned my attention to sorting the intake out, I'm gonna have to use the Fenton 3 x 2 as can't find an aluminium intake to mill out, Only one person making one and its big money, there is one guy making blower intakes for the Y block but at $1000 he can keep them !!!
The problem I have is the carb throats on the Fenton are too far apart for the bottom outlet of a 4/71, a 6/71 would of been spot on but way to big for the look I want. Anyways decided to stick with what I have, shame really as the Fenton seems to be fairly rare.
My cunning plan is to fabricate a curved ended box to act as a plenum which simply bolts to the existing intake and the blower bolts straight to this.

First job was to make a 3/8" plate for the base and transfer all the various holes, the original carb mounting holes will be drilled out to 3/8" as because of the top having the normal 5 degree inclination the holes will be slightly tilted once I flycut the top surface true to the crank centreline, the pics hopefully will explain.



http://i65.photobucket.com/albums/h2...psyyjjxd7o.jpg

http://i65.photobucket.com/albums/h2...pstvkorsph.jpg




Here I have made a mockup in cardboard.



http://i65.photobucket.com/albums/h2...psxzylnbbj.jpg

http://i65.photobucket.com/albums/h2...psx0zkzyqd.jpg




Getting to the rear 2 and the front 1 mounting bolt will be tricky but doable



http://i65.photobucket.com/albums/h2...psbuznjtqv.jpg

http://i65.photobucket.com/albums/h2...pstwe5an78.jpg


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Cereal boxes are good for lots of things! :)

Thats nice machine work !

Very Nice, This is filling in the puzzle I have always wanted to know, I have a book on overhauling a blower for street use but it stops shy of the blower drive, never been real crazy about thinking I was going to have to tear into my working 6/71 on my '32 just to see what it would take to machine a drive. I have a front cover already and a 392 laying around....Nice work and thanks for the info & great pics! Matthyj

Wonderful cad work

Cardboard aided design

Quote:

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Originally Posted by firebird77clone

Wonderful cad work

Cardboard aided design

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Pmsl !!!

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Got the blower case back from the blasters so set about doing some modifications to it, First the support bar in the intake side was removed, its not needed now its not hanging on its side anymore, once out the edges were milled to clean it all up.



http://i65.photobucket.com/albums/h2...psu38ckpzv.jpg

http://i65.photobucket.com/albums/h2...psosocngdh.jpg




Heres a pic of a stock scavenge pump setup incase you have not seen one.



http://i65.photobucket.com/albums/h2...pse1b6lave.jpg




My small mill doesnt have enough throw to flycut the intake angle out so popped into my mate Brians shop and used his. While I was there the intake throats were bored out from 1.250" to 1.500", the bottom plate of the plenum was bolted in place and both bored together to keep the throats aligned.



http://i65.photobucket.com/albums/h2...psp8dfrjw9.jpg

http://i65.photobucket.com/albums/h2...ps1z3g4lqc.jpg

http://i65.photobucket.com/albums/h2...ps20tbysps.jpg




Correcting the intake angle meant losing the rear stud hole, we spotted it through first and retapped, Will weld a bung in here at some point.
The dividers in the throats will be ground to a knife edge so as not to disturb the flow.



http://i65.photobucket.com/albums/h2...psefgdfbvt.jpg




The bracket bosses cast into the intake no longer serve a purpose so cut them off and blended them smooth, this uncoved a hole so it got welded shut,



http://i65.photobucket.com/albums/h2...pshvdkjf9k.jpg

http://i65.photobucket.com/albums/h2...ps47pkuqyk.jpg

http://i65.photobucket.com/albums/h2...psicazpses.jpg




Here the plenum sides are tacked in place, the tricky to get at bolts are now much easier to get at as they go through columns.
Couldn't do any finish welding as my 200amp isn't gonna be big enough as the aluminium is 1/2" thick, gonna need a fair bit of preheat on it.



http://i65.photobucket.com/albums/h2...psnmzk7hly.jpg


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Looking good. Just becareful, the critics claim those intakes don't work well................. Mine worked fine though. :LOL: You are doing awesome work on it!

.sorry double posting

More progress, I tacked the plenum together ready for final welding but due to it being 1/2" plate my 200amp machine was not gonna do the job without a lot of preheat so it was off to see Mr Miller Dynasty Got it all welded together late in the evening eventually, then had to drink numerous cups of tea while it cooled down Thanks Gary



http://i65.photobucket.com/albums/h2...psz8px1v5m.jpg

http://i65.photobucket.com/albums/h2...psdraqz9sj.jpg

http://i65.photobucket.com/albums/h2...psnsxzcy2w.jpg




One of the mounting lugs on the intake had been damaged at some point so this was built up with weld and reshaped.



http://i65.photobucket.com/albums/h2...psvfxohbut.jpg




The bottom plate thats bolts to the inlet bowed by about 20 thou over the length so it got a small fly cut on the mill. If you have never seen flycutting i've added a short video below.



http://i65.photobucket.com/albums/h2...pss4vuzsu0.jpg

https://www.youtube.com/watch?v=ZWbo84vSLv4




I mocked it up to have a look and discovered the front plate is a little shy in 2 corners so will have to make up a couple of bits and welded them in.



http://i65.photobucket.com/albums/h2...ps9cpsgww6.jpg

http://i65.photobucket.com/albums/h2...pseicvbsdx.jpg




Next up was the snout drive shaft, its 1.250" steel bar turned done to be welded in to the hub at the blower end, the other end I have to broach a keyway into, made up the pulley flange. the shaft has been left long at the moment so I have something to hold on, I will shorten once its all mocked up on the motor.



http://i65.photobucket.com/albums/h2...pst5bnkx8z.jpg

http://i65.photobucket.com/albums/h2...psow8taqet.jpg

http://i65.photobucket.com/albums/h2...pshbbkirt6.jpg




I was a little concerned about the mounting bolts on the intake not being very far apart, probably be fine but just to be sure I added a pair of braces, they have to be welded to the intake yet, they bolt to the 1/2" blower plate with 2 x 1/4" bolts.



http://i65.photobucket.com/albums/h2...psfmttoggu.jpg

http://i65.photobucket.com/albums/h2...psvl2z9imn.jpg

http://i65.photobucket.com/albums/h2...psfac5tlaj.jpg




Here it is mocked up in place ready to measure for the snout length.



http://i65.photobucket.com/albums/h2...psipmbo1l6.jpg

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Wow you're sporting some awesome aluminium work there, this should be a fast beast when your done!

We played around with the iphone video a bit last night and were surprised at the results we got !!!


https://www.youtube.com/watch?v=st0Dg0QWu-0

https://www.youtube.com/watch?v=przxBnHk6UA

https://www.youtube.com/watch?v=NXRjioXZD2c


We had the ceramic glowing nicely !


https://www.youtube.com/watch?v=yRs9R7JCKxY

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The amps had that torch singing on that base plate eh?:)

I hope the viewers also noticed those practiced hands guiding the torch and feeding the filler...............very skillful my friend.

Quote:

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Originally Posted by stovens

Wow you're sporting some awesome aluminium work there, this should be a fast beast when your done!

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Cheers Steve

Been busy as usual today but not that much to show for it, I usually mount my coils behind the dash but thought I would have a change this time, I got some of these OBT coil covers and thought the cast look would go well with the other parts under the hood, was a bit disappointed with the design really, nice concealed mounting points but then they go and put a grub screw right in the front, could of easily been put in the side where you wouldn't see it
I'm running a MSD blaster coil and a MSD 6A ignition box behind the dash out of sight. Will paint the top of the coil black later.



http://i65.photobucket.com/albums/h2...psaqgbbb1k.jpg

http://i65.photobucket.com/albums/h2...pstq7g2xbz.jpg

http://i65.photobucket.com/albums/h2...ps1zddptk0.jpg




Was going to make a carb plate for the 2 x Edelbrock 94's but found one of my suppliers made a nice carb plate already and not expensive, check out Dashmans hotrod parts Dashman's, Hot rod and custom speed equipment parts



http://i65.photobucket.com/albums/h2...pslx45swxf.jpg

http://i65.photobucket.com/albums/h2...ps6hlgtskk.jpg




Also the headlights from Willys Reproduction Parts arrived so it now has a face



http://i65.photobucket.com/albums/h2...pskyjynmgq.jpg

http://i65.photobucket.com/albums/h2...ps6q1ofa0b.jpg

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Another double post ??? not sure whats happening here ???

The truck's looking super cool, Steve, or as our friend Dave Severson used to like to say, kewl man, very kewl!

Wow, looking good Steve but one question, will those carbs and scoops clear the the low scoop on the bonnet ? I relise you haven't cut the hole out yet but to my southern upside down eye it doesn't look as if you will be able to close the bonnet, hood for our American friends, using those air scoops on top of the carbies.

Quote:

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Originally Posted by rspears

The truck's looking super cool, Steve, or as our friend Dave Severson used to like to say, kewl man, very kewl!

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Cheers Roger, funny you should mention Dave, I was only thinking the other day that I hadn't seen Dave on here lately ??? Also Dave ICI2

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Quote:

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Originally Posted by Whiplash23T

Wow, looking good Steve but one question, will those carbs and scoops clear the the low scoop on the bonnet ? I relise you haven't cut the hole out yet but to my southern upside down eye it doesn't look as if you will be able to close the bonnet, hood for our American friends, using those air scoops on top of the carbies.

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Hi Whip, I cut the hole a few days ago, didn't put a pic up because it didn't seem that interesting.


http://i65.photobucket.com/albums/h2...psd7d0o2ef.jpg

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Quote:

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Originally Posted by roadster32

Cheers Roger, funny you should mention Dave, I was only thinking the other day that I hadn't seen Dave on here lately ??? Also Dave IC2.

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Yeah, both Dave's walked away by their own choice, and it would be nice to see their moniker's pop up again! Who knows, maybe it'll happen!

Glad you eased Whip's mind with that picture of the hole under the scoop. Can't leave a Kiwi fretting, right? ;):):D:LOL: