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-   -   New frame for an old WILLYS (http://www.wranglerforum.com/f118/new-frame-for-an-old-willys-96174.html)

garage gnome 05-31-2011 08:08 PM

New frame for an old WILLYS
 
Hey Guys,

I started to build a new frame for The Jalopy. The stock 2A frame twists really easily and the construction is weak. The strongest flatty frames are the 3A/B frames. I don't happen to have another decent one of those laying around, so here it goes. :)

I started this last week on Friday.
http://i748.photobucket.com/albums/x...j/100_7250.jpg

http://i748.photobucket.com/albums/x...j/100_7252.jpg

It may not look like much now, but I have some great ideas for it. :firedevil:
http://i748.photobucket.com/albums/x...j/100_7253.jpg

http://i748.photobucket.com/albums/x...j/100_7251.jpg

Then today, I brought it to school and capped all the ends and welded diamonds on the joints. These multiply the strength of the joint by 3 times or so.
http://i748.photobucket.com/albums/x...j/100_7270.jpg

I also called up Endangered Species Jeep in Holyoke MA. They have a stock set of used TJ Rubicon springs in like new condition. It's starting to come together! :thumb:

Kevin 05-31-2011 11:25 PM

Nice!:thumb: The build will be fun to watch and you've really got your work cut out for you!:wavey: Keep the pics coming!

TnDz TJ 06-01-2011 05:24 AM

OOOOOH!!!! Nice work! I'll we watching this one! I wish I had the room for a L O N G project....sigh....

garage gnome 06-01-2011 05:18 PM

Thanks guys, glad you like it. :)

I picked up my coil springs today and mocked them up under the frame. :firedevil: I took some measurements, the center of the Jalopy frame sits 18" off the ground right now. The new frame will sit 26" off the ground when it is on the axles and 31s. Thats an 8" lift! :eek: I might pick up another couple of inches when I put the spring mounts and bushings on too.

I referenced the Jalopy to my stock 3A. The 3A sits at 17" with 29s. So that means it has stock height springs in it, but they are not the stock springs. They are 5 leaf 1/4" thick...

http://i748.photobucket.com/albums/x...j/100_7273.jpg

94 yj 06-02-2011 10:09 AM

Quote:

Originally Posted by garage gnome (Post 1274503)
Thanks guys, glad you like it. :)

I picked up my coil springs today and mocked them up under the frame. :firedevil: I took some measurements, the center of the Jalopy frame sits 18" off the ground right now. The new frame will sit 26" off the ground when it is on the axles and 31s. Thats an 8" lift! :eek: I might pick up another couple of inches when I put the spring mounts and bushings on too.

I referenced the Jalopy to my stock 3A. The 3A sits at 17" with 29s. So that means it has stock height springs in it, but they are not the stock springs. They are 5 leaf 1/4" thick...

http://i748.photobucket.com/albums/x...j/100_7273.jpg


Very cool start to a build. Nice welds and but I think you need a heavier jackstand for the front of that frame!
-John

garage gnome 06-02-2011 10:25 AM

Thanks! Yeah, the I beam was the only thing I could find that would make it sit level.

If anyone wants to, you can peruse this thread about a matching trailer I built for the jeep in my avatar.

Building a trailer for my jeep

garage gnome 06-02-2011 08:14 PM

I made some more progress today. Since I have no channels to run the wiring inside the frame to protect it, I bent up a piece of 1/2" EMT for it. After I run the wiring, I am going to silicone up the ends to keep the mud and crap out. I think I'll run another bigger one on the other side for the battery and winch cables since one battery will be located in the back and the other might go under the dash...

http://i748.photobucket.com/albums/x...j/100_7278.jpg

Then, I was going to work on making up some bumpers, but then I remembered I need a power steering box mount. I'll have to notch the crossmember a little for the steering shaft.

http://i748.photobucket.com/albums/x...j/100_7279.jpg

I welded on a piece of tubing with the ends cut a 45 and capped that too.

http://i748.photobucket.com/albums/x...j/100_7284.jpg

And to mount it, I'm going to plasma cut some holes and weld some 7/16" pipe to run the bolts through and keep it water tight. The outboard side will be flush with the frame, but the inboard will stick out a little to compensate for the saggy box contour.

http://i748.photobucket.com/albums/x...j/100_7285.jpg

BPJOOP93 06-03-2011 01:33 PM

Nice work so far. what are the specs on the toy? what budget?

deathphoenix99 06-03-2011 01:38 PM

Wow, that is awesome!

deathphoenix99 06-03-2011 01:50 PM

Love that trailer you built! Very nice job on it! Also like the little touches you added, like the Vin plate, but dang, that Jeep looks tiny compared to the trailer.

garage gnome 06-03-2011 06:03 PM

Quote:

Originally Posted by BPJOOP93 (Post 1278896)
Nice work so far. what are the specs on the toy? what budget?

The Jalopy currently has a 225 Dauntless V6 mated to a T18 with the 6.32:1 first and D20. The axles (gear ratio of 5.38) are Dana 25 front and 41 rear which I may change out to a 44. No lift currently. Has a crawl ratio of 69:1 which I can easily change by putting a D18 transfer case in and bump it up to 84:1. From the time I got it to now, I figure I have less than a grand into it. Once this is done, It will probably around $1500 or so and now that school just let out, I can make some $$$. :cool: I probably have a quadrillion hours into it though. There was a lot of :banghead: while fixing the PO's screw-ups. :rofl: It had an about blown 3 spd, no floors, the engine was all screwed up and a bunch of other little stuff wrong with it. That's why I have a few junkers. :D

Oh, and did I mention how much it cost to get? :D $0.00


Quote:

Originally Posted by deathphoenix99 (Post 1278924)
Love that trailer you built! Very nice job on it! Also like the little touches you added, like the Vin plate, but dang, that Jeep looks tiny compared to the trailer.

Thanks! I worked really hard to make it look vintage as possible and to match the jeep closely. Actually, the trailer and jeep are both 10 feet long. Sometimes it is a little interesting to stop, like when an idiot cuts you off. :mad::eek: Originally, it had 9" brakes with cam adjusters and single MC. I upgraded the brakes to 10" with modern adjustments and a dual MC.

garage gnome 06-03-2011 06:37 PM

I finished up my power steering box mount and crossmember notch.

I started out by marking out the four mount holes and plasma cutting the holes in.

http://i748.photobucket.com/albums/x...j/100_7286.jpg

Then I cut my four pieces of pipe to length and I didn't have any 7/16" bolts long enough, so I cut the heads off some to use as alignment pins to tack the pipe in place.

http://i748.photobucket.com/albums/x...j/100_7288.jpg

And finish welded those up.

http://i748.photobucket.com/albums/x...j/100_7289.jpg

Then I had to notch my crossmember. This one really hurt. :(

http://i748.photobucket.com/albums/x...j/100_7291.jpg

And welded in a chunk of 4" pipe and voila! A nice power steering mount. :)

http://i748.photobucket.com/albums/x...j/100_7296.jpg

Next, I'll build some bumpers and I'll have to figure out a nice way to mount the warn 8274. Then after that, I'll have to tear the Jalopy apart... :'( I'll miss not being able to drive it for a while.

garage gnome 06-04-2011 05:19 PM

I made a rear bumper today, nothing special.

http://i748.photobucket.com/albums/x...j/100_7298.jpg

And I started on the front one too. I only tacked it on so I can take it off to make winch mounts. I also put the frame up on all four springs. It's really bouncy. This thing is going to be rugged but have a nice ride to it. :firedevil::cool:

http://i748.photobucket.com/albums/x...j/100_7302.jpg

I think I will have to build a guard for the power steering box. It hangs kinda low...

http://i748.photobucket.com/albums/x...j/100_7303.jpg

garage gnome 06-05-2011 12:24 PM

I finished up making the bumper and marked out the holes for my winch mounts.

http://i748.photobucket.com/albums/x...j/100_7305.jpg

I did the same thing as I did for the ps box mount. I cut holes in with the plasma cutter and welded some pipe in. I cut in a place for the cable and welded some flat stock in to keep it water tight.

http://i748.photobucket.com/albums/x...j/100_7306.jpg

I welded the bumper on and that makes the actual frame DONE! :) Now the fun stuff begins like suspension and body and motor mounts.

http://i748.photobucket.com/albums/x...j/100_7307.jpg

TheTJRod 06-05-2011 07:24 PM

Looking awesome man! You do all your welding with no gloves? Hell I burn my hand/arm when wearing a mechanics glove on the hand not holding the gun. I have to wear a leather glove. You using gas?

Your attention to detail is awesome. Just went through trailer build and wow. Where you going to welding school, I want to go there.

Edit: Your welding looks to nice and clean to not be using gas. Man I need to pick up some gas.

garage gnome 06-05-2011 08:35 PM

Quote:

Originally Posted by TheTJRod (Post 1282965)
Looking awesome man! You do all your welding with no gloves? Hell I burn my hand/arm when wearing a mechanics glove on the hand not holding the gun. I have to wear a leather glove. You using gas?

I usually do, but today I didn't. Now I have a nice sun burn...:facepalm: Gas? Yeah, the MIG welder needs it, or are you talking about torch welding?


[QUOTE=TheTJRod;1282965Your attention to detail is awesome. Just went through trailer build and wow. Where you going to welding school, I want to go there.[/QUOTE]

Thanks! In a small town called Huntington MA.

TheTJRod 06-05-2011 09:00 PM

Yea I'm talking MIG. I use flux-core and I have a whole bunch of splatter. Gas is suppose to help it splatter less and and no slag, need to get me some.

garage gnome 06-17-2011 08:22 PM

I got some more work done. I haven't really done too much in the past 2 weeks due to school stuff and work. I got my front coil spring mounts pretty much finished up. That was a lot of work.

After making some measurements, I found out that the distance between the point where the axle tube is welded to the knuckle is 36" and my frame is 29" wide. The coil springs are 5" in diameter too. Dang it. I had to notch the frame quite a bit to get them to fit properly.

http://i748.photobucket.com/albums/x...j/100_7315.jpg

It ended up being 1/2" thick. :eek: So I made up this 3/8" plate to weld in there.

http://i748.photobucket.com/albums/x...j/100_7316.jpg

http://i748.photobucket.com/albums/x...j/100_7317.jpg

http://i748.photobucket.com/albums/x...j/100_7318.jpg

and I welded a support on the back.

http://i748.photobucket.com/albums/x...j/100_7320.jpg

And then I had to beef it back up some more, so I used some 6" pipe as my coil spring mounts.

http://i748.photobucket.com/albums/x...j/DSCN0087.jpg

and the axle mounts

http://i748.photobucket.com/albums/x...j/DSCN0091.jpg

http://i748.photobucket.com/albums/x...j/DSCN0092.jpg

and I mocked it up on a junk axle. The short axle tube is exactly 5" long and I hit it perfectly! :D

http://i748.photobucket.com/albums/x...j/DSCN0089.jpg

Mortalis5509 06-17-2011 09:07 PM

Nice welds.

Jeep_Geek 06-17-2011 09:57 PM

lookin good! Its a shame you had to notch that beautiful frame you built, but that crap always ends up happening one way or another. keep it up, cant wait to see the end product.


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