Dirtrider's Willys Wagon Build

dirtrider

Bigger Hammer
May 19, 2016
111
Kalispell, Montana
First Name
Steve
Willys Model
  1. Wagon
Willys Year:
  1. 1962
After a year of creeping around here I figured it was time to start my own build thread.

First, a little about myself. I grew up building cars with my dad with my first being a 1966 Rambler (don't judge it was a cool car!) and we owned and restored a couple of Marlins. Around this same time, we switched pages and built a 23 Ford T bucket street rod with a small block and 9" ford rear. It was a very fun car but limited on how much we could drive it due to the open top and no fenders. While still owning the T, we built a couple of 49-52 Chevy trucks with Nova subframes, 10 bolt rears, and small blocks with autos. These were very fun and one my dad drove daily for years. My senior year in high school, a friend ran from the cops, hit a fire hydrant, and ended up with a DUI and jail time (due to other offenses in the past). Since he was going to jail for a while, he offered to sell me his 69 Dodge Super Bee with a 383 and factory 4-speed. This is the car I had drooled over and dreamed about even before I knew what girls were!

This car started a long line of Mopar muscle cars for many years including a 69 Charger R/T, a 68 Charger R/T, another 69 Super Bee, a 69 Coronet R/T, and a 70 Challenger R/T. There were more but you get the idea.
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In 2003 I had always wanted a Jeep and traded my 69 Super Bee for an 03 Rubicon. I immediately started modifying it and had an absolute blast with it. Unfortunately around 2010, the cars, Jeep, and 70 Dodge Power Wagon that I owned at the time had to be sold due to a divorce.

Rebounding from the divorce, I built a linked YJ with Dana 60's, coil overs, ARB's, NV4500, Howell fuel injection, etc. It was a LOT of fun but just a little too hard core to enjoy unless we were on a hard trail.
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I sold it and bought a 2000 TJ which I still have. It's pretty mild but has an 8.8 Ford rear, 4:88 gears, Ox Lockers, winch, OBA, Currie steering, etc.... This Jeep is a lot of fun and gets driven and wheeled a lot. It and the dirt bikes will give me some stress relief while building my Willys.

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Enough about me. On to the Willys!

A few years ago, while doing training for Search and Rescue, we were in a helicopter and we flew right over the top of a Willys wagon. I did some research and found out a friend owned it and had for 14 years and it was stored at his moms place. I didn't even know he had it. I had always wanted one and tried to buy it but he wasn't budging. Then last June he called me out of the blue and said he was moving to Seattle and would sell the wagon. I hooked up the car trailer and was there the next morning with cash! When I arrived he was weed eating all the weeds that had grown around the wagon. This is how it looked the day I picked it up.

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Once home, I partially assembled and cleaned what was there to take stock in what I had and start with a build plan since I didn't have the original engine, trans, or transfer case. Overall the wagon is in really good shape with very little rust and other than the drivetrain, is pretty complete. I'm only missing the rear seat, driver's door handle, and driver's side mirror.

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More to come........
 

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Jeez Steve, you're gunna fit right in here. Welcome and looking forward to your build thread.
 
Beautiful mopars, and nicely built jeeps

Excited to see were your willys goes

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As stated in another thread, take a little time to decide what the end use of the wagon will be before tearing it apart. Decide upon your "build plan" ahead of time. Stick to the plan, be it mild or wild, and do things once the way you want it done! You will find the folks on this forum very helpful if you need anything. Very nice starting point you have there. Good luck and enjoy!
 
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Almost seems too nice to modify. But since the original drivetrain is gone...
 
Welcome from Colorado, Steve. It's always good to see another Old Willys Truck Getting Saved. Nice Intro too! Pivnic
 
Thanks for the warm welcome! Pivnic, I spend quite a bit of time in Colorado as my oldest daughter is a welder/fabricator in Grand Junction and my little bro lives in Berthoud.

When I first got this wagon, I had originally considered keeping it completely stock but adding a Warn overdrive. I even found a trans and transfer case for it but finding a complete motor that wasn't junk was very difficult. For months I thought about what I really wanted to do with this wagon and basically it came down to the fact that I really want to drive it and drive it a lot! I've had garage queens in the past and they sit too much, you have to worry if it's raining outside, you worry that somebody may park too close to you in a parking lot and put a ding in it.......etc.

My fiance' and I love to travel and camp off of a KTM Adventure and in 3 more years we will be empty nesters and want to travel even more and further. We also want to be able to include our Siberian Husky in a lot of these trips.

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We see ourselves using the Willys as an expo/camping rig and already have a loosely planned trip to Alaska in it. We want to explore Alaska, the Western US, and Baja with it and do it in comfort. I high priority is also simplicity, reliability, and enough power to carry us and gear at modern highway speeds which a stock Willys is unable to do plus be able to handle moderate to above moderate trails.

My first plan was to use a Wagoneer frame and axles with a 4.3 V6 so I picked up a Wagoneer for free with a bad engine and a good running 2000 GMC Envoy with no title for cheap that had a 4.3 Vortec and 4L60E trans. After looking the Wagoneer over closely I didn't like that the fuel tank was along the drivers side frame, the rear axle was offset and not a Dana 44, and I would have to shorten it to get the 106" wheelbase I wanted.

On to plan B which was to use the original frame but extend it 6" for longer front leaf springs, box it in, use the Wagoneer front axle, and find a centered rear Dana 44. This has been done by a lot of people and works great but a lot of work since you have to fabricate almost everything except body mounts.

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After a TON of research here and on Pirate4x4.com, I finally decided to use a K5 Blazer chassis. It was a hard decision as I've never been a Chevy guy but it made sense. The exact wheelbase I wanted and I could use everything! Frame, axles, motor 5.7 TBI (fuel injection!), trans 700R4 (overdrive!), power steering, power disc brakes, and a very big and rear mounted fuel tank with passenger side fill so I could still use the original filler position. I also like the fact that I could get parts at any parts store from Alaska to Mexico. I picked up an 87 Blazer for $1800 that ran great and I drove it for 3-4 days to make sure everything worked great then stripped it the very next weekend to my neighbors horror! They thought I was going to fix it up and are Blazer fans. Lol

In one week, I got rid of the Wagoneer...donated it to a good friend for his project, sold the Envoy for a $500 profit, and stripped the Blazer and sold what I didn't need for $1000 so I'm not quite ahead, but I'm not out much and have a complete and great running drivetrain.

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I have this stripped to the bare frame now but haven't gotten a picture yet. So as of right now, this is where I'm at. The Willys body is unbolted but resting on the original frame, the Blazer is stripped, and now I need to power wash and degrease the Blazer chassis. If I can find some help, I may try to get the Willys body set down on the Blazer frame to start doing measurements on how far the motor has to come back and to start planning body mounts.
 
Sounds like you have a solid plan, Steve and maybe most important, high motivation. Good luck and keep the pics coming.
 
You have some good taste in vehicles! Welcome to the weird Willys world. Definitely keep pics coming and update us on your build. Are you with your local county's SAR? I've been a member of ours in Park County WY for about 7 years. It's fun, exciting and exhausting all at the same time. Good luck with your build.
 
Thanks! I was in SAR for quite a while but quit about a year ago as we bought a house too far away to get there in an emergency. Driving way too fast it still took me an hour to get to a call. I do really miss it though.
 
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Here's an updated picture of the Blazer the way it sits now.

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Ive also been looking for killer deals on CL for tools. I bought a Lincoln welder a month or so ago and picked up a cut off saw today for $40!
 

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Made some great progress yesterday. FINALLY got the Willys body on top of the Blazer frame. Right now it's sitting on wooden blocks and it's way to high, but it will drop down a good 6-8" once I cut some brackets out of the way. Next week I'll get the air chisel out and get any brackets and old body mounts off of the frame that I don't need. Also, I can start planning my body mounts and get all the measurements I need for moving the motor and trans back in the frame. It's exciting to kind of visualize the final product.

The old frame:
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And the new:
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Does anybody here have a Wagon on a Blazer chassis that can take a picture of the very rear of the body and frame? I would like to see how others have made the body drop down over the frame in the very back. Any help would be appreciated!
 
Go to youtube. Search willys wagon K5 frame. There is a post about 4 minutes 30 seconds long by a guy Classicjoe100.

I was trying to copy and paste but it did not want to work on my phone.

About 1/2 way through there are pictures of how he chopped the rear valance to let the fuel tank and chassis run long. It looks like he dropped it on nice and low so the stock K5 ride height looks like about a 4inch lift on the wagon. Nice height in my opinion.

I did that on my K5 swap 30 years ago then dropped diamond plate over it.

My current build is on a Wagoneer chassis. I bobbed the back about 4 inches. On your K5, that will mess with your fuel tank etc. The beauty of your K5 frame un cut in the back is the bigger tank or a burb 32 gallon bolts right in giving you some serious range.

With mine, I just plopped the body down on 1/2 inch plywood spacers between the straights in the chassis then went to town fabricating the mounts. Pretty straight forward. I changed the grill mount to using 2 mounts instead of just one. Hopefully it will flop around a little less than stock. There are already 2 access slots stamped in the bottom channel of the grill. I drilled in alignment with those for the new mounts so I can get in to hold the mount bolt head.

Hopefully this helps.

Duane.

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That's exactly the information I was looking for. It might be the worst video on Youtube, BUT I was able to get an idea how he did clearanced the rear valance to make it fit. I agree on the stance. I was hoping to run 35's with no lift at all or 37's with a 2" lift. My goal is to have it drive and steer very well.
 
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The same guy has a couple short videos of it for sale. It has a great stance and should drive just like a K5 minus a little weight.

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I hope so. That was the biggest reason I decided early on to ditch the stock drivetrain. I wanted something I could drive a lot and keep up with modern traffic and in comfort. I'll check out his other videos. Thanks for the video link!
 
Here is a link to my build.

http://www.oldwillysforum.com/forum/showthread.php?t=8085

I used what I had in scraps and from other projects to fab body mounts. It will just give you some ideas.

Check out my rear fender butchery. That idea will allow for 35's on your build with the ability to wheel it.

Also if you are not familiar with Square Body Chevies, be sure to pull your steering gear and reinforce the frame there. They are prone to cracking. Easy fix, easy beef up compared to the scope of your project.

Post tons of pictures.

Good luck.

Duane

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