Farfrom - 1963 Willys Wagon

Time for some updates. All of this work was from late spring, but I hope to get some time to start working on the wagon again.

I removed a section of the passenger floor at the door opening as well as the rocker, rocker support and two floor supports.

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I bought a new rocker support as well as the two floor supports, but the forward floor support did not have the correct floor contour. So I cut it, bent it and welded in a section to close the gap.

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Then I made a new rocker panel and started the process if welding everything together.

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Finally I moved on to the passenger fender that was bent from a previous fender bender. I made a template from the driver side so I could determine the proper contour. Then I pulled the fender into shape and welded the tares in the metal. The final shape turned out pretty good.

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Decided to add some color to a few areas. I painted around the door opening, rocker panel and cab corner because those areas will either be difficult to paint well when the door is installed or covered when the fender is installed.

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Painted around the fuel filler area so I can reinstall the filler neck.

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I'll come back later and wet sand the rest of the unpainted areas as well as the areas where the paint overlaps into the cab corner area and the quarter panel area when I'm ready to commit to more painting.
 
Time to catch everyone up on recent progress. I removed the passenger door to begin rust repair. The lower inner section as well as the outer section needed a lot of repair. So I cut out the sections needing replacement and made a new piece for the inside and bought the outer piece.

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I cleaned up the surface rust on the inside and used some metal prep on the areas that had some pitting.

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Next I did some test fitting of the replacement pieces. I also tested the pieces on the wagon before final welding

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Welding of the replacement pieces is done and the welds have been cleaned up.

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Back to checking fit of the work after the welding is compete.

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I took some time off the wagon project to prepare my TJ for a Rubicon trip. So not much work was done on the wagon over the summer. However, now it is time to catch up on some recent work.

This is the driver floor area.

I ended up cutting out more than I wanted, but the underside was worse than the inside.

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I don't have a bead roller, so I thought I could improvise for such a small area. I made a repair section and cut along the center line of where the lower part of the bead will be. Then I bent the bead area to match the angle and welded the gap.

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Next up will be driver door repair and rocker panel extension.
 
Nice work! What kind of machine are you using for your welding?


I dread the day I need to do the cab work on my green '48...
 
Brilliant idea. I have been monkeying around with a solid rod over a trough in plywood trying to push a shape into it with my bearing press. I am going to copycat your idea. Thank you for sharing.

Duane

Sent from my SM-G920V using Tapatalk
 
Dual48s said:
Nice work! What kind of machine are you using for your welding?


I dread the day I need to do the cab work on my green '48...
Click to expand...

I'm using a Craftsmen 110 mig welder. I've had it since 2003 and it works fine for what I use it for. I started out with fluxcore wire and switched over to gas a few years ago.
 
On to the driver door

This door was the worst off when it comes to the amount of rust. Both doors needed outer and inner panel work, but this one also needed work on the vertical edge where the door meets the quarter panel.

The outer panel is a patch panel I bought. The inner panel with the stepped area that aligns with the floor and rocker was hand made.

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Here you can see some of the inner panel repair already in place.

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I like to test fit the door once the inner panel is in place.

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Here the outer panel is complete.

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Another test fit once the panel is done and it is a relief to see the alignment is good.
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On to the windshield frame. I could see there was some rust on the bottom around the driver side. After I removed the windshield I could see that all of the top and a large portion of the bottom area would need to be replaced.

I used two sign posts, some wood, two step ladders and several clamps to rig up a scaffold work area. I have to say it was very uncomfortable and awkward at times, but allowed me to get close to the work area. I also used two welding blankets to protect the inside from grinding, cutting and welding.

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At this point I have the passenger side top area replaced and working on the driver side top.

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Now it's time to move on to the lower section.

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I have a few fine details to attend to before I can consider this done, but it is roughed in pretty well at this point.

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Good job on fixing it. Make sure you put a straight edge right along the pinch seams around the opening you just repaired. Left and right of the V top and bottom and down each side. These should be dead flat to stop strain on the seal causing leaking. You don't want the same problem back again in a short time!
 
Gojeep said:
Good job on fixing it. Make sure you put a straight edge right along the pinch seams around the opening you just repaired. Left and right of the V top and bottom and down each side. These should be dead flat to stop strain on the seal causing leaking. You don't want the same problem back again in a short time!
Click to expand...

I never thought about strain on the seal, but getting a good straight line is one of the cleanup items I have remaining. It's a little hard to see in the last photo above, but there is a faint green line that shows where I need to grind to for the rest of the repair.

Thanks for the tip.
 
I've been traveling a lot the last 2 years for work. As my work project winds down I am looking forward to being home more and getting back on my wagon project. Hopefully I'll have some sort of an update soon.
 
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