55/59 Pickup/Wagoneer build

Since I bought the truck I figured I'd start a build thread right off the bat. For background, there are two threads I started when trying to decide whether or not to buy it. Intro and frame identification.

In summary, I was originally told it was a 55 (and the title shows 55) but the serial number indicates that it's a 59. I'm not sure that it makes a ton of difference, though, because the only original Willys parts are the cab, hood, grill and fenders. From what I gather so far (with help of members here), the frame is an early 70's Wagoneer frame.

The engine is a 350 SBC from a 70s or 80s pickup, although this is surprisingly hard to identify even with numbers, any help on this would be appreciated! I haven't tried to ID the transmission yet. There will be questions about this eventually.

My first goal was to see if I could get the engine running and make decisions about drivetrain etc. from there, so first things first: carb rebuild. But the first stumbling block was that a previous owner had cut off the choke tower of the Holley 4-barrel, which is where the list number is stamped. With some help from Holley, I think it's a 750CFM which is apparently too big for a stock 350, so either the PO didn't know what he was doing, or this is modified engine. Based on the intake and exhaust manifolds, I suspect the former so I'm looking for a 600CFM carb, rather than try to rebuild a questionably modified and over sized one. In the meantime, I'll check compression and see if the electric fuel pump works. Then I can try to start the engine. Once that's sorted and I can drive it up and down the driveway once or twice, I'll blow it apart and start the real work. I just have to decide what to do about the sketchy engine cross member, incorrect front axle placement, minimal frame and body rust, missing interior.... and on and on and on.

My end goal is for a reliable, comfortable driver. Not a show winner but something that is nice to look at and can be comfortable driven long-ish distances. This is going to be a challenge...

Here is a link to my build. I am putting a Wagon on a 79 Wagoneer.

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

Very similar frame to yours. I think the rear suspension may have changed a little between our frames.

To relocate the front axle, you would be moving the steering gear forward as well. If the bed length is not a big deal to you, I would consider moving the cab and engine back on the chassis. If you look through my build, my body mounts were not rocket science.

If you want a little more wheelbase, the rear springs on mine are not drilled on center for the index pins. I would think you could move the rear axle back by redrilling

The good thing is it's already seen some butchery so no fears of wrecking what some might scream the old Keep it Stock slogan.

Whatever you decide, be prepared to change directions a few times. I know I have.

Welcome aboard from California.

Duane

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Awesome. Looking forward to following your progress.

Thanks! Duane, I had come across your build when I was researching Waggy frames and definitely need to read it in more detail. You're right about the steering, and I would probably want to re-do the body mounts anyway. They're probably structurally ok, but not pretty. I'm already pondering ideas about moving the rear axle. And yea, you're right, the fact that it's already chopped up is kind of relieving. In some ways I wish it was more original, but on the other hand it frees me up to do different things. Either way, seems like most people on this forum anyway are pretty open minded.

Also, thanks to Craigslist, I picked up a new carb (with surprise intake included) for $225, all brand new never installed! Also picked up a fuel pump and battery while I was out. I'm pumped, can't way to get this thing running!

Made some progress today. Installed the new fuel pump, then pulled the intake and started cleaning up getting ready for the new one. I don't have gaskets yet and there is still some work to be done before final install, but wanted to see it with the new intake and carb. This is fun

Well, big progress yesterday. The engine ran for the first time in at least 5 years. I installed a new mechanical fuel pump (previous setup used electric), new carb and intake, new valve covers (cause the new intake didn't have an oil filter and neither did the old valve covers). Other than that, I patched together a lot of the old plumbing and fortunately the electrical wasn't too bad.

The first time I turned the key, I just heard a loud click. The battery was charged so I pulled the starter and connected it on the bench and it ran fine. I'm thinking the brushes were just rusted enough to keep it from moving with the resistance of the engine. With it reinstalled it turned over fine. Next I checked the compression, 7 cylinders were between 150 and 165, one down closer to 125. The 125 is a little concerning but not enough to prevent it from running, so I put the plugs in, dropped the fuel line into a gas can and cranked it over.

Initially, it blew a bunch of fuel back out of the carburetor so I was worried I had a timing issue of some sort, but after a few more tries it fired up, and once it warmed up it idled pretty well! Every now and then it cut out with a fresh spray of fuel from the carb, but I tweaked the distributor a bit and it seemed to help. I'm fumbling in the dark on that one. Regardless, I definitely need to set the timing and the carb needs some tuning, but overall it ran pretty well! I'm anxious for it to move under its own power but I need an actual fuel tank and plumbing for that.

I'm not sure what to do next. All along I'd been thinking if the engine ran, I'd just start tearing it down to do the frame and body work needed, but now I'm thinking I'd love to drive it, so I'm not so sure. On the one hand, I'd have to do a lot of work to get it ready to drive, then I'd end up tearing a lot of that work down again for the rebuild. On the other hand.... I want to drive!

It's exciting though!

Edit: I don't know how I forgot the 3-hour oil-filter extraction. Holy crap that thing was on there! Many choice words were uttered!

Nicely done, Luke. Making great progress and keep up the good work.

I was 10 years old when my first go cart ran for the first time. 45 years later I still feel like a 10 year old when these projects come to life. Savor the victory. Very cool progress.

Duane

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Ha! I had a similar experience growing up. And I was pretty giddy yesterday when it fired and ran

Well no major progress this weekend but definitely a major milestone.

I was going to make a dump run Friday and one of the things I wanted to get rid of was the old fuel in the fuel cell that a previous owner had installed. Unfortunately, the way he'd installed it, the cell had to come out of the top. On the bright side, the only thing attaching the bed to the frame were the fuel hoses going to the massive electric fuel pump. So I cut the fuel lines, lifted the bed off the frame, popped out the old fuel cell and off to the dump I went.





Then with the rest of the afternoon I decided to see if the truck would move under its own power. I'd tried it a few days before with no luck, so I added some ATF to the (TH350?) trans, ratchet-strapped a fuel can to the bumper, and tried again. Low and behold, we have motion! Hell, it was satisfying enough just to light the engine off again. I've burned a gallon of fuel already and it hasn't even left the driveway



So now I'm that much closer to doing the minimum to get this thing safely driving on the road and try to get some seat time before I do the major tear-down and rebuild. Now if you'll excuse me, I'm going to do some shopping for '70 Wagoneer fuel tank and associated plumbing.

Oh, and I also made the sad discovery that the Yosemite Sam on the back windshield isn't a sticker but etched into the glass.... so I guess I'll be looking for new rear glass

i kinda like that etched into the glass. but then again i am weird.

Auggie said:

i kinda like that etched into the glass. but then again i am weird.

Click to expand...

Ha, I'd agree with you if it were something personalized for me. I'm not really a big fan of the Yosemite Sam look, unfortunately.

I had a decent weekend. Nothing earth shattering. A lot of research and $ spending. I ordered a fuel tank and sender/pickup. Also ordered a throttle pedal, an oil filter for the TH400 and some other odds and ends.

On the truck, I cut a few brackets to attach the bed to the frame out of an old hunk of angle iron. Eventually the bed mount will all be completely re-done out of steel, but since I'm hoping to drive it some before doing the major tear-down, this will hold the wooden bed supports to the frame for now.

While I had the portable band saw out, I went ahead and cut off that old fuel-cell frame that the PO had bugger welded on.



And finally, I managed to get the rear drums off to check out and clean up the internals. Not in bad shape.



Again, they'll be replaced eventually but they're serviceable for some around-town driving.

Quick update from last week. I spent a bunch of time researching and ordering parts.

First I got a new fuel tank for the Wagoneer frame. It's an MTS Model 0020. I'm severely disappointed, for 2 reasons.

1. The fuel pickup and senders are secured by these crappy scraps of metal that appear to have been cut out using an old shear and not even bothered to be cleaned up



2. The brackets that the tank came with to attach it to the factory Wagoneer frame are junk, I don't understand how anyone would feel comfortable using them. Unfortunately I didn't get pictures of those, but suffice it to say, I won't be using them.

Overall, though, it's a fuel tank that I think I can make work. I'll have to fabricate a better mounting solution and clean up the sender/pickup hold-downs but I can make it work. Here it is mocked into place



I also picked up some heat shields (Classic Industries #TF700526) for the Ram Horn exhaust manifolds to protect the spark plug boots. I'll need to make up new cables so I can route them correctly down along the oil pan and up behind the heads, instead of up and over the valve covers, right past the exhaust manifolds as the PO had them.



Last, I received and crudely installed a throttle pedal (Billet Specialties 199175). I thought about getting one of the Lokar-style floor mount pedals, but I need as much leg room as I can get so I didn't want anything sticking through the firewall. Sadly I was in a hurry anxious to start the truck up and turn it around in the garage so I didn't take my time getting the cable lined up perfectly with the pedal. But, a lot of the floor pan will have to be cut out and replaced eventually, probably including the trans tunnel, so it'll get fixed eventually. It will work for the time being.




This is where I get caught trying to decide how far to go to get the truck driveable vs. just tearing it down and starting the restoration. Eventually I'll be re-working the rear frame to move the axle rearward, which will then move the fuel tank and plumbing etc. But to get it running now, I need a secure mount for the tank, and plumbing. It's hard doing work I know I'll be re-doing, but I think it will be worth it in the long run to get some seat time before I tear the truck apart. Soooo, next will be fabrication of a semi-temporary support structure for the fuel tank and the associated plumbing.

Wow, that is pretty bad how they expect you to hold the fuel pump in place!

Yes I was disappointed to say the least after spending $200... I'm definitely going to have to make something to improve on that.

Haven't made any major progress on the Willys, but did get the YJ out to Rausch Creek this weekend. Nice to get out of the garage once in a while.

Well I made some progress but I'm not sure how happy I am with it. For the long run I'm planning to build a skid plate out of 1/8 plate for the tank to strap into, then attach the skid plate to the frame, much like in a YJ or TJ. But in the long run everything will be moving, so this is more of a short term temporary-ish solution so I can get it on the road. I hate doing things this way and it's making me want to forget about driving it and just tearing it down, but I think I'd regret that in the long run. I think seat time will be important to future decisions.

Anyway, the rough skeleton is there, it needs more structure and support but it's progress. Once it's solid I'll start on the plumbing...

Finally finished repairs/upgrades to the YJ after my last off-road trip and back on the Willys. Had a friend cut out some rings on his plasma table to replace those jagged tabs the fuel tank came with.

Next on to plumbing.

Well progress has been quite slow but there has been progress.




I started out by bending the line to go along the frame rail and across the transmission cross member. I couldn't make it all the way to the front and still be able to fish it in so there is one union.


Then I plumbed from the fuel pump up to the carb using all hard line and AN fittings. This seemed a lot cleaner than a rubber line.


Then the line from the fuel tank to the frame.


And last, I dug out an old fuel gauge to calibrate the sender to the plastic replacement tank. I'm glad I did because it must be a little different from the original steel tank. I had to shorten the float arm about a half inch so it doesn't hit the top or bottom of the tank before the gauge reaches either extent. Hopefully the new gauge won't require much tweaking cause that took the better part of an afternoon, but at least it's right!

That's all for now. I'm hoping to get more done over the holidays.

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