Grand Willys Project

[Gojeep]

Door sections have been welded together making a 115mm-4.5" longer door.


I noticed before even welding the door together that there was a lot of crown in this part of the door.


The ends look alright. You need some to stop drumming and oil canning. Checked the other side, which have not been worked on at all, and was the same.


I just used a 5" shrinking disc on my grinder to heat up a 4" square section at a time until it turned a honey colour and then quickly hit with compressed air to shrink it. Do need to be careful not to overlap the areas as you go along as it will create waves where it pulls more on the double shrink.


I'll leave it at that I think as worried any more could cause a 'loose' panel where it flops in and out.


There was a mismatch at the top of the door due to the outside of the door having a slight curve and the inner door being flat as goes up against the glass. Going to move the fold inwards to match it by placing the bolster under where I want the new fold to go.


Hammering down along the edge of the bolster starts to move the fold across.


Once I have the new fold line where I want, I just helped the fold by squeezing it.


Bit more dressing on the side of the fold with a heavier bolster behind it and looks better.


So this side is done for now so will start on the other side to get it to the same stage before moving back to this side again.

[Gojeep]

Not sure if to show bits like this, but here it goes.


I was unhappy how the bottom of the cowl blended into the rest of the door sill. Every day when sitting down to take my boots off. I would see it!


It is perfectly flat and think it would look better with some curve to it. Will make it the same as higher up in the cowl.


After cutting the underside of the cowl free, I tack welded the slide hammer to the straight flange. Only took a few hits for it to pull outwards along with the bottom of the cowl around the WILLYS pressing as well.


Tacked the slide hammer in about 6 different places to create the curve.


Think it blends better now. Then welded the underside of the cowl back again keeping the curve.


Had to then do the other side as well. For a few hours work, it was worth it to stop it annoying me!

[bodgie]

I agree, the curve looks finished and way better.

I'm happy to see these updates, I'm sure others will too.

Jason

[bruggz351]

Not sure if to show bits like this,

Most definitely, man.

Originally Posted by Gojeep

Think it blends better now.

Isn't it amazing, how the smallest of changes can make such a marked improvement. I can see how that would've stuck, in your eye.

Thanks for the update, man....

cheers

[rustynuts]

Been watching avidly. Your work is amazing Marcus.

[Tyvokka]

You're a coach builder, Marcus!

[4WD4FUN]

Small change fixed now is easier then later and looks amazing. Your work is neat and tidy and so is your work shop it’s been a pleasure a small bit of jealousy to watch this thread from the start can’t wait to see end result.