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

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Originally Posted by cffisher

Looking good a job I don't envy. There are times I wish I could do that.

To be honest Charlie once you get the hang of how much resin to put on the mat its pretty much an easy process, to dry is weak and too much is weak, the key to success is to find that sweet spot and a few decent rollers.

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Got a bit more done, these lighter evenings are a real bonus, firewall finished up now on the inside,








I started thinking about the master cylinder and pedal placement so decided to get it out of storage ready for a trial fit, opened the master cylinder box and spotted a small problem, I had set the brake bracket up with a 54 F100 cylinder but had ordered a 55 cylinder, I didn't even know they were different, the bores the same but the bolt hole configuration was way out, I thought about cutting a new bracket out but decided to make an adaptor from a piece of 1/2" aluminium plate, the pics explain it all.














Next I found a piece of stainless and turned up a pedal pad, found a piece of rubber in an old mat.










One thing that I didn't like was the horrible black plastic cap on the master cylinder so machined up a cover to glue over the plastic one, machined a slot for the plastic cap ears to fit snugly in and gave it a knurl on the outside and glued it in place.














The output of the cylinder was 1/2" unf and i'm trying to use brass brake fittings on this car, mainly because I like them, Couldn't find a fitting in brass so made one up on the lathe. I found a brass 90 - 1/8" npt to go into it but had to make a 3/8" tube nut, couldn't tap the 1/8" npt thread as someone borrowed my tap and havn't bought it back yet !!!








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Not much progress as had a few interuptins yesterday but now the firewall is in i started to put some steel framework in and mounted the door hinges.











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I just noticed that your going to use a single outlet master.. or is this not going on the road?

That wouldn't be allowed here in the state of Massachusetts with our new rules. For a street vehicle, it has to be a dual reservoir / dual discharge master cylinder.

Curious if it's the same "over there"?

Originally Posted by 34_40

I just noticed that your going to use a single outlet master.. or is this not going on the road?

That wouldn't be allowed here in the state of Massachusetts with our new rules. For a street vehicle, it has to be a dual reservoir / dual discharge master cylinder.

Curious if it's the same "over there"?

I noticed the same thing this morning as I was reading through the latest. I don't believe that it would be a "not allowed" issue for me here in Kansas, but all of the roller packages have dual circuit MC's installed.

Nice work on the brakes, bracing, firewall, etc, etc, etc as usual, Steve. I look forward to your updates and often learn from your photos and descriptions.

Originally Posted by rspears

I noticed the same thing this morning as I was reading through the latest. I don't believe that it would be a "not allowed" issue for me here in Kansas, but all of the roller packages have dual circuit MC's installed.

Nice work on the brakes, bracing, firewall, etc, etc, etc as usual, Steve. I look forward to your updates and often learn from your photos and descriptions.

Under "our" new rules, If it was an original vehicle then it would be fine, for an all new build - nope.. must meet the new standards.

Originally Posted by 34_40

I just noticed that your going to use a single outlet master.. or is this not going on the road?

That wouldn't be allowed here in the state of Massachusetts with our new rules. For a street vehicle, it has to be a dual reservoir / dual discharge master cylinder.

Curious if it's the same "over there"?

Lots of classics running single circuit brakes here, to be honest I have run them for years without any problems but I always use all new parts.

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Originally Posted by roadster32

Lots of classics running single circuit brakes here, to be honest I have run them for years without any problems but I always use all new parts.

Thanks for the reply. And that's the rub! A "classic" for us has to be original. Your car will be an assembled vehicle and need to meet the current standards. So you can't run a single reservoir/discharge master cylinder.

If that was an original Willys from the 40's you'd be fine.

Thanks for the chat.

Originally Posted by 34_40

Thanks for the reply. And that's the rub! A "classic" for us has to be original. Your car will be an assembled vehicle and need to meet the current standards. So you can't run a single reservoir/discharge master cylinder.

If that was an original Willys from the 40's you'd be fine.

Thanks for the chat.

This will be regarded as a classic as it's registered 1943

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Originally Posted by 34_40

I just noticed that your going to use a single outlet master.. or is this not going on the road?

That wouldn't be allowed here in the state of Massachusetts with our new rules. For a street vehicle, it has to be a dual reservoir / dual discharge master cylinder.

Curious if it's the same "over there"?

Sounds like you guys have similar laws up there.. I haven't looked in our book,,but I'm quite sure we have to use a dual circuit master cylinder in our new builds as well.. I used a 94 Mustang unit on the F100,when I rebuilt that,,mainly cos the old original was poked,,and I had the Mustang unit on hand..
Steve,,looking good,man.. You gunna have a fair bit of room in that cab,are ya?? Curious to see how you fit in there..You are a similar height to me aren't you??

Originally Posted by lamin8r

Sounds like you guys have similar laws up there.. I haven't looked in our book,,but I'm quite sure we have to use a dual circuit master cylinder in our new builds as well.. I used a 94 Mustang unit on the F100,when I rebuilt that,,mainly cos the old original was poked,,and I had the Mustang unit on hand..
Steve,,looking good,man.. You gunna have a fair bit of room in that cab,are ya?? Curious to see how you fit in there..You are a similar height to me aren't you??

Yes Robin it's nowhere near as tight as I expected, keeping as much as possible of the firewall has helped, I'm 6ft 198lbs

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Originally Posted by roadster32

Yes Robin it's nowhere near as tight as I expected, keeping as much as possible of the firewall has helped, I'm 6ft 198lbs

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All good.. You got to be comfortable in these things.. pointless building them,,then finding you can only drive for 45 minutes,,give or take,,and having to stop to stretch your body back into shape..

More steel framing today, I wanted to tie the inner steel work in to the frame so first job was to make a pair of brackets, and fit to the frame and firewall.










Next I looked at a problem I have been thinking about for a few days, the problem is on the willys you can't bring the tube frame down to the floor level because there is no recess anywhere for it to fit into, this is my solution, basically a 3 sided box bolted down to the floor and tied into the inner fender panel and also tied into the firewall brackets.








I also got to make the roll cage front bar bracket that is bolted into the chassis and front outrigger.





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Looks good,Steve.. All you can do with that situation..But it will be strong..Nice.

Very nice work and I like your reinforcement solution as well. Are you going to use stainless for the roll bar/cage too?