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

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Originally Posted by roadster32

Just wanted to wish everyone a very Happy Xmas and a prosperous New year.

Same to you and your family! Tell Sue we said HELLO!

Well with xmas finally done and dusted i can get back into the workshop, heaven !!!
I got straight back onto the drilling of the axle that I had already started, all went well but I came across 1 hole that just won't drill no matter what I try !!! Its like a hard vein in the steel, I tried a brand new milling cutter but it just dulled the cutting edges, had it on the last one of these axles but managed to get all the holes done, I'm gonna pop to the machine shop tomorrow and see if my mate Brian has something to do the last hole.








This is the bit that won't drill





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That is some nice work! That's pretty crazy it won't drill. It'll be interesting to hear what he says on how to cut it. I've had semi axles that we had to drill for aftermarket air ride kits and we had these problems. We took the axles down to a shop that had a laser and they took care of them. That is not an option for this poor guy.

Back when I was installing overhead cranes in factories or where ever they sent me we would occasionaly have that happen with the steel base plates. It was almost always with foreign steel. Seems there would be COAL in the steel you couldn't even torch it out with out much difficulty

We are going to try a carbide drill this morning guys, fingers crossed it will do the job

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Well Steve, if Brian can't get it for ya have your sign painter buddy paint a hole. With his talent it should be a snap!

Or just fill in the matching one on the other end

that's what I was thinking also-------------

Ah guy's have Faith! This is Steve we are talking about, he's resourceful and always figures these things out, making stuff way over our heads seem easy! Maybe drill int in stages with different diameter bits as he goes up in size?

Originally Posted by Bob Parmenter

Well Steve, if Brian can't get it for ya have your sign painter buddy paint a hole. With his talent it should be a snap!

Ha ha ha, Hello Bob, havn't seen you around here for a while or have you been hiding

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Originally Posted by cffisher

Or just fill in the matching one on the other end

Originally Posted by jerry clayton

that's what I was thinking also-------------

Trouble is it would look goofy, can't be having that !!!

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Thanks for the vote of confidence Steve, The other holes are drilled in various size stages but this one just wipes out the drill edges.

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Steve, is it feasible to apply some very localized heat to that hole center area without affecting the overall strength of the I-beam, and would that perhaps help?

Well the machine shop is shut today so the hole in the axle will have to wait, I've being getting bits and pieces made so when a bit of decent weather comes by I can attack this with a vengeance and get a rolling frame together in a day, Today i made up the firewall mounted brake pedal assembly.

Its all 1/4" BMS, could of got away with 1/8" but it just doesnt have the look.

Heres the main bracket








Next spun up a phosphor bronze bush for the pedal pivot. Pedal is 1/4" BMS but with a 1/8" BMS stiffener, makes it into an I beam












Heres the finished assembly, had to use the master cylinder of my 26T project as the one I ordered hasn't arrived yet.





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Originally Posted by rspears

Steve, is it feasible to apply some very localized heat to that hole center area without affecting the overall strength of the I-beam, and would that perhaps help?

Yes it shouldn't be a problem Roger, If the mega expensive drill don't do it we will try the heat, cheers for that.

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