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

Been doing some more sitting down jobs A previous owner of the body had done a hack job on the area where the door card sits and only left 1/2" so first job was to repair and build out the flange.



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Next I started thinking about door cards, I had tufted diamond in my coupe so decided to do something different on the truck, decided on aluminum
panels that would match the seat, first job was to cut a piece of 2mm sheet to size, anything thinner would drum & resonate on a street car,
Next the holes were marked for the handle spindles and attachment bolts.



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Next a piece of aluminium was plucked from the scrap bin and gave up its life to become finishers for the handles. holes were drilled in the panel to hold these in place with 5mm button heads with filled heads to resemble rivets.



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Next I cut the top layer out with the plasma cutter and cleaned up all the edges with a flap wheel, added a few holes to make it tie in with the seat and be a bit more interesting.



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Here it is assembled.



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So that is an awful lot of rivets one has to drill out if one needs to get inside the door to do a repair Steve or are they false rivets and only a select few hold the panel on ?

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Originally Posted by Whiplash23T

So that is an awful lot of rivets one has to drill out if one needs to get inside the door to do a repair Steve or are they false rivets and only a select few hold the panel on ?

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Looks like the perimeter is button head screws

Great work Steve! That will set it off nicely!

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Originally Posted by Whiplash23T

So that is an awful lot of rivets one has to drill out if one needs to get inside the door to do a repair Steve or are they false rivets and only a select few hold the panel on ?

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They are button head bolts Whip, you need to zoom in

Looks great Steve! Hope that foot is feeling better soon!

Another example of; what would we do without our lathe and mill?


Jack.

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Originally Posted by Mr Blue

Looks great Steve! Hope that foot is feeling better soon!

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Fancy seeing you here young fella !!! Cheers Don

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I know, back in the hot rod saddle! Hope you are well Buddy!

I think I can see a small change of plan coming, cut the windows out last night and the Red is not very see through unlike the Orange on my coupe



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Something about Rose Colored glasses comes to mind...
You are doing amazing things as usual!

Well more or lees the inner doors are now sorted windows go up & down really smoothly so turned my attention the the outer skins, as usual one of the former owners had done a hack job on the window opening returns, most of it had been chopped back, they couldn't even cut straight ffs !!! makes you wonder why ??? they needed extending inwards, not much about 1/2" but the gap to the window was massive !!!

First job was to key the old glass all the way around and feather the edge.



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Next some cardboard (I favor Fruit & Fibre boxes as the resin don't stick to them and its nice with cream on it, but any will do) was taped into place to support the glass to be added.



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Once cured the cardboard and tape is removed and this is what your left with, I usually give it a key and add one layer of mat on this edge. then finally trim to size required. I shall be adding a return for some window fuzzys at the bottom.



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Looks great as usual!

Good to see glass work done right! And clear, concise explanations with good pictures, too - Bonus!! You're a good one, Steve!

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Originally Posted by rspears

Good to see glass work done right! And clear, concise explanations with good pictures, too - Bonus!! You're a good one, Steve!

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Ahh, where's the bondo? This can't be correct..

More great work Steve!

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Originally Posted by 36 sedan

Ahh, where's the bondo? This can't be correct..

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This extension may have been a better application for Bondo Hair, 36 sedan. ;):rolleyes::LOL::LOL::LOL:

Steve, please don't be offended. We're just poking some fun.....

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Originally Posted by rspears

This extension may have been a better application for Bondo Hair..

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SEE, I knew it was wrong! Lol

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Originally Posted by Mr Blue

Looks great as usual!

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Thanks buddy

Quote:

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Originally Posted by rspears

Good to see glass work done right! And clear, concise explanations with good pictures, too - Bonus!! You're a good one, Steve!

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Thanks Roger, there are other ways of doing it no doubt, this one has always worked well for me

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Originally Posted by 36 sedan

Ahh, where's the bondo? This can't be correct..

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Hahaha, I usually only use it to final finish, the glass paste you guys call hair has its uses but I only use it for filling and dips or slight shallows.
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Quote:

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Originally Posted by rspears

This extension may have been a better application for Bondo Hair, 36 sedan. ;):rolleyes::LOL::LOL::LOL:

Steve, please don't be offended. We're just poking some fun.....

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I have a thick skin Roger lol
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I prepped the topside of the window opening by feathering and laid up one layer of glass mat, this was then sanded smooth and a quick coat of primer to see how it looked, came out ok



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next I laid the skin on the inner and marked it to give a 1/4" gap on the window, the excess was cut off and the edge sanded smooth, looks much better now.



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You do fabulous work my friend.

Awesome job & will last forever! Do you ever back up the backkside afterwards with fiberglass cloth? Great rod building. Matthyj

Yeah, you don't want too much of that English heavy rain falling into the inside of the doors that could result in bad rust aye. Have you decided on the colour of your side windows or you going to settle on the red ?
Thanks for posting with detailed photos of the fibreglass repairs and additions as I have learnt from you on how to repair the chopped up body on my T Roadster.

Yep detailed photos on glass work are very helpful! Keep em coming Steve and have a Dickens' Cider on me at the pub! :)

Ordered some orange tinted yesterday and it arrived this afternoon so after tea I cut the windows out using the red as a template, Its quite surprising how more see through the orange is.



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



And heres a up & downy video clip, nice and smooth



https://www.youtube.com/watch?v=rKPe7D2dHaw
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Wow, big difference! And the orange looks pretty cool too!

Looks great and operates as slick as . . . well . . . glass. I have that same mechanism, and I love it.

BTW, do you have light transmission standards for the driver/passenger side windows? In Texas, it's 25%.

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Originally Posted by 36 sedan

You do fabulous work my friend.

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Thanks bud, I just do the best job I can, I'm sort of self taught with fibreglass
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Quote:

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Originally Posted by Matthyj

Awesome job & will last forever! Do you ever back up the backkside afterwards with fiberglass cloth? Great rod building. Matthyj

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Thanks Matthy, I like to use mat because of the random strands that lay at different angles but occasionally I will add cloth but I find the cloth more awkward to work into shapes, Mat vs Cloth seems to be 50-50 argument between users, I find it does have its uses on large open areas though.
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Quote:

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Originally Posted by Matthyj

Awesome job & will last forever! Do you ever back up the backkside afterwards with fiberglass cloth? Great rod building. Matthyj

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Thanks Matthy, I like to use mat because of the random strands that lay at different angles but occasionally I will add cloth but I find the cloth more awkward to work into shapes, Mat vs Cloth seems to be 50-50 argument between users, I find it does have its uses on large open areas though.
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Originally Posted by stovens

Yep detailed photos on glass work are very helpful! Keep em coming Steve and have a Dickens' Cider on me at the pub! :)

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Steve ya can't beat a dickens cider !!!

Not much but any progress is better than none I guess, I had some duplicate gauges kicking around so though I would put some in the firewall, Didn't want them flush fitted as that would look a bit boring so spun up a couple of rings out of a bit of thick wall aluminium tube to stand the gauges off slightly, a bit of aluminium sheet and an hours work and this is what I ended up with



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That looks great!

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Originally Posted by 40FordDeluxe

That looks great!

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Thanks Ryan,
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Last night I decided to fit the other gauge panel on the opposite side but realised I had screwed up !!! I completely forgot that the brake servo was right behind the panel Well i always say its not how you screw up but how you get out of it that counts
Easy answer was to make the gauge spacers a bit longer, the first ones were 1/2" so a bit more of the tube was turned and this time the spacers are 1.125" long, Funny but now they are on I think the longer ones look better.



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I like the longer look too.

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Originally Posted by 36 sedan

I like the longer look too.

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Thanks bud, I sort of found out by accident :LOL:
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