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OT: Retro Wrangler/Willys Pickup (long)

bigwalton said:
I think it's fantastic!!! :bow: :bow: :bow:

It's all the practice I got you with the holes in the top panel, admit it ;)

Thanks guys!

All I admit is that I really really don't like body work. I don't like sheet metal welding either. I'm very glad there's only one significant piece of sheet metal welding/body work left on the project, which is the roof panel.

Jeff
 
I'm very glad there's only one significant piece of sheet metal welding/body work left on the project, which is the roof panel.

Did I miss something? How does all of this get joined together without welding/bodywork?

This looks great. Wish I had the time, talent and tools to be able to something 1/2 as involved. Keep it up I think a whole lot of us on this board are living vicariously through you.
 
shawnboy said:
Did I miss something? How does all of this get joined together without welding/bodywork?
JB Weld and Bondo......:eek:
 
shawnboy said:
I'm very glad there's only one significant piece of sheet metal welding/body work left on the project, which is the roof panel.

Did I miss something? How does all of this get joined together without welding/bodywork?

This looks great. Wish I had the time, talent and tools to be able to something 1/2 as involved. Keep it up I think a whole lot of us on this board are living vicariously through you.

No, I don't think you missed anything... what I said was there's only one SIGNIFICANT piece of sheet metal welding/body work, which is the roof panel. Joining the Brute tub closeout to the LJ tub is a couple of very short seams and a bunch of plug welds, no big deal. They've done a nice job designing the cab closeout assembly, so it's not a lot of sheet metal welding or body work.

All the rest of the welding is heavy duty stuff on the frame, bed mounts, etc. - which is easy welding compared to 19-gauge sheet metal :-)

I hope you're all enjoying watching the build as much as I'm enjoying actually doing it (except of course, for the aforementioned sheet metal welding and body work!).

Jeff
 
jscherb said:
No way I'm using any of either of those products on this project!
I hope everyone knows I'm totally kidding. Every thing I've seen you do is 1st class work.:bow:
 
jscherb said:
No way I'm using any of either of those products on this project!

Wait, so there isn't even a skim coat of filler on that patched panel on the top????

:huh: :crazy: :huh: :bow: :bow: :bow:

How'd you get it that smooth?????
 
Dang, Jeff...lookin good. This thread is an inspiration!
 
bigwalton said:
Wait, so there isn't even a skim coat of filler on that patched panel on the top????

:huh: :crazy: :huh: :bow: :bow: :bow:

How'd you get it that smooth?????

Yes I did use filler, but I did not use Bondo. Bondo is filled with talc, which can absorb water and promote rust. The talc makes it easy to sand, but it can be somewhat porous.

I did a base coat of All Metal, which is filled with powdered aluminum. That goes next to the metal and protects from water. It is also extremely tough so it is much more durable than talc-filled products.

Then I did a finishing coat of "Icing", which is a very fine self-leveling polyester finish coat.

EDIT: At most the filler is 1/16" thick. In most places it is about the the thickness of 19 gauge sheet metal (roughly 0.040").

But no Bondo. ;)
 
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Ok, sorry, I was thinking of Bondo in the generalized "Kleenex" usage.

Whatever it is, it looks awesome.
 
I don't see how it's all going to stay together without duct tape. I can lend you a few feet if you need.
 
shawnboy said:
I don't see how it's all going to stay together without duct tape. I can lend you a few feet if you need.

My daughter just built a boat with duct tape for a High School physics project; I think she's got a bit left over that I can use, but thanks for the kind offer :)
 
jscherb said:
My daughter just built a boat with duct tape for a High School physics project;

Ok, you know you have to post pics of this somewhere... ;)
 
Kristen's boat is still at school, she says she's not quite finished with it but I can have pictures when it is done. The assignment was to build a two-person boat using cardboard and duct tape. They are supposed to test them in the school's pool when they are complete. That should be very interesting.

Progress update on the main subject of this thread:

Since I'm going to use painted front flares on the pickup to better harmonize with the rear fenders, I picked up a used set of wider painted Sahara flares a while back on eBay. They were painted white, so I'm in the process of painting them Flame Red now. I experimented on the rears first, since they're not part of the end result of the build, and they turned out well enough that I'm now doing the fronts. Below you can see the rears pretty much finished (when the paint has hardened about a week I'll probably buff them to perfect the shine), and some of the front parts on the bench in primer and first coat of color. It's a bit hard to get a factory finish with rattle can paint, but I think I've got it worked out.

Should be done with them by mid-week and will install them on the LJ. Just one more task I can tick off while waiting for the house to be done.

I did order the bed last week and they told me it would be about three weeks before it arrived. I have some customizations being done to it (actually, the customizations involve NOT including features, leaving out things like fender bolt holes, tailgate chain holes, etc.), so they have to build the parts custom and then ship it to me. So about 2 1/2 weeks until that arrives.

Jeff

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CJ-7 World Cab roof panel

(Eric, you might want to avert your eyes even though this is only "digital cutting")

In between waiting for coats of paint to dry on the flares, I decided to do a photo-simulation of the CJ-7 roof panel to give me a better idea of the modifications required to make the panel fit.

First photo below is the model for reference.

Second photo is a doctored photo of the CJ-7 roof panel as it will be modified to fit the lengthened CJ-10a World Cab rear panel. Matches the model pretty well :)

Third photo is a simulation of the -10a roof lengthened to fit the modified -10a rear panel.

Final photo is an undoctored photo of the CJ-7 top panel sitting on the -10a cab. You can see where I'll have to shorten the panel, and how I'll have to move the rear part of the drip rail down and insert filler panels so the back part of the roof is as high as the middle part.

No question in my mind that the -7 panel profile is way better looking than the flat -10a panel. The flat -10a panel just looks too boring to me.

This effort was just for planning purposes - I won't be able to do these mods until the tub is complete and that's some way off...

Jeff

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Finished painting the flares to match the LJ. Now I have to wash and wax the LJ before I put these on or they'll make the LJ look bad :).

Probably will install them Thursday, I'll give the paint a chance to harden up some more before I handle them too much.

Not sure I'll like the painted look better than the black look, but painted flares on the front will be necessary to integrate with the painted pickup fenders on the rear.

Jeff

Flares2.jpg
 
jscherb said:
My daughter just built a boat with duct tape for a High School physics project; I think she's got a bit left over that I can use, but thanks for the kind offer :)

Like father like daughter.... starting her out with duct tape first building boats? I guess it won't be too long then before she's building Jeeps like her old man.

When can we expect to see her work from wielding an electrode?
 
I didn't know if I'd like them but now that they're done I gotta say I actually like them better than the black ones that I could never keep clean or black. Finish came out as good as the factory finish on the LJ, not bad for rattle cans. I did have to wash and wax the LJ so it looked as good as the freshly painted flares. :)

I think these will go just fine with the painted rear pickup fenders, definitely will go better than the black ones.

Probably no real work will happen on the pickup project now until the bed arrives, that's still two weeks away.

Off topic - anyone going to the Antique Truck Show next weekend in Macungie, PA?

Jeff

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jscherb said:
I didn't know if I'd like them but now that they're done I gotta say I actually like them better than the black ones that I could never keep clean or black. Finish came out as good as the factory finish on the LJ, not bad for rattle cans. I did have to wash and wax the LJ so it looked as good as the freshly painted flares. :)

Flares3.jpg


Flares4.jpg

That looks great, jscherb. I like it better than the stock ones, too.

Craig
 
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