Page 1 of 8 1 2 3 4 5 ... LastLast
Results 1 to 20 of 147

Thread: '49 Jeep Willy's Pick-Up Truck Build Thread

  1. #1
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default '49 Jeep Willy's Pick-Up Truck Build Thread

    Guys my GF and I just picked up a '49 Jeep Willy's 4WD Pick-Up Truck for our new project.

    It came with a 350 SBC/TH350 out of a '77 Chevy pick-up as well as the stock D18 twin stick transfer case and the stock front and rear axles (Timken rear/D28 front).

    Our plans our to build this thing up into a WWII themed hot-rod (but off-road) Willy's.

    I should have taken some more pic's before I started the tear down, but I have one decent shot of the Willy's prior to starting to remove bodywork yesterday.

    This week I scored a set of 40x13.50x17 BFG MTR's mounted on Hummer H2 wheels and this weekend I will be picking up a matched set 14-bolt rear/D60 front axles (with brakes and hardware) out of a '73 Chevy pick-up.

    We're gonna build it big and it will have a lot of cool WWII stuff on it including some pin-up art.

    I can't upload pic's right now for some reason, but I will as soon as I can.
    Last edited by atomicjoe23; 08-21-2009 at 05:23 PM.
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  2. #2
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Deconstruction Day 1

    Yesterday I pulled the bed off of the frame (a little harder than it should have been since a previous owner decided that welding the bed to the frame in a couple of spots was a good idea???), pulled the hood, front fenders, and grill shell off of the front end as well.

    I dropped the gas tank and removed the fuel lines as the truck has been sitting for 10 years and although I could get it to start using starting fluid at the carb it wasn't drawing any fuel so I'm gonna replace the whole fuel system. . .while I'm talking about it here's the fuel system plan. I'm gonna convert a stainless steel beer keg into a bed mounted gas tank and use -6 braided line and fittings for the entire fuel system. I have found some vintage looking aluminum finned fuel filters and coolers that I'm going to use as well. I haven't fully made up my mind about the fuel pump yet, whether I'm gonna stay with a block mounted mechanical pump or go with a frame rail mounted electric pump.

    Then I got out the angle grinder and wire wheel attachment (too bad I don't have my own sandblaster/air compressor) and I got rid of all the surface rust on the outside of the frame (not inside the C-frame yet) from the back to the cab. I'm gonna pressure wash it to get rid of as much of the junk out of the inside of the frame rails and then coat it Eastwood's Rust Converter followed by Eastwood's Rust Encapsulator and then follow that up with OD green.

    Not bad for one days work all by myself!

    It's not allowing me to post pic's at the moment, but I will as sson as I figure out what the problem is.
    __________________
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  3. #3
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Deconstruction Day 2

    Today I pulled the radiator today (it's an aluminum one. . .so I'm gonna spray it flat black with Eastwood's Radiator paint) and re-wire the fans to be pullers instead of pushers the way the previous owner had it set-up. I also pulled the wiring harness (an EZ-Wiring 18 circuit aftermarket universal harness the previous owner had started) after labeling all the terminals that were already hooked up (wasn't much. . .starter, alternator, water temp sensor/gauge, pusher fans, and the ignition. . .just enough to get it running) and I pulled the cab body mount hardware. All of this in preparation to pull the cab off the frame so I can finish getting rid of the surface rust and prep it for paint.

    Next up, pull the drivetrain so that I can start cleaning that up as well. . .but first I need a bunch friends to come over and help pull the cab. . .it's heavier than the bed and I nearly busted a gut getting that off all by myself. . .definitely not gonna try removing the cab alone!!!

    I'll post more pic's once the administrator fixes my settings. . .
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  4. #4
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default

    Found something funny out today. . .went to go pull the wheels/tires off to get ready for the axle swap (picking up the Dana 60 front/14-bolt rear tomorrow. . .guess that's today now). . .turns out on these crazy Jeep axles the driver's side lug nuts and wheel studs are REVERSE FREAKING THREADED!!! I have NEVER seen or heard of that before. . .the passenger side are normal and the driver's side are reverse thread. . .go figure!
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  5. #5
    Registered
    Join Date
    Mar 2001
    Location
    Des Moines, Iowa
    Posts
    338

    Default

    yep a lot of old vehicles were that way. Working on mine and forgot about it awhile ago.
    1947 Jeep Willys Pickup

    1959 FC-170

    1971 DJ-5B

    1974 J20

    87 Grand Wagoneer

    01 TJ Sport "Mr Bungle"

    06 Jeep Commander

    1995 Black Grand Cherokee limited 5.2 liter (retired)

    1994 Black YJ (retired)

  6. #6
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default

    Today we got the cab off of the frame. . .that took quite a while considering we're working out of a car port and a garden shed type garage!!!

    We also got the engine/tranny/transfer case pulled. . .and we picked up a D60 front/14-bolt rear axle set, the guy also threw in a 5-spd. manual trans. and an NP-205 transfer case. . .all for $250! What a STEAL!!!

    Tomorrow's plans are to remove the current "wimpy" axles from the frame and get the frame on jackstands. . .remove all the surface rust from the frame and get it ready for paint. We'll also be separating the engine/tranny/transfer case to clean and prep for paint!

    I'm gonna try to also get all the pictures uploaded to Photobucket so that we can post up the progress picks so far. . .this project is really flying along at the moment. . .we're hoping to have it back together and driving by the end of September!
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  7. #7
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default

    One thing I noticed while tearing it down (and I'm fairly new to 4WD's so bear with me), but the D18 twin-stick t-case front driveshaft output (front driveshaft wasn't installed when we bought it) appears to route the front driveshaft to interfere with the TH350 oil pan???

    Has anyone run this combination before??? I'm gonna check Advance Adapters website in the morning to see if they offer anything to fix the problem. . .initially I just figured I would get a clocking ring (I figure with 40-42" tires and the purpose of the vehicle a little bit of ground clearance sacrifice isn't a huge deal. . .I'm building a custom crossmember for the tranny/t-case already that even if I clock the t-case would leave me with the same amount of ground clearance I already have. . .not including the additional clearance I'm gonna gain with the 40's), but then I stopped and thought about the shift levers. . .right now the go through the floor pan just fine and I can use them, but if I clock the t-case it's gonna change the orientation of the shift levers. . .getting them through the floorboards would be the least of my concerns. . .I'm much more worried about being able to actually use the T-case than cutting a hole or enlarging a pre-existing hole in the floors.

    I would post a pic, but the Willy's is already stripped to a bare frame and I figured that I could figure the t-case problem out as I'm cleaning/stripping/painting everything else for re-assembly. . .

    One thing to keep in mind is that I have two NP205 t-case's sitting in the garage. . .if you guys think that would be better. . .let me know. Like I said I'm new(er) to the off-road side of things so I'm still learning the strengths and weaknesses of different parts and pieces!

    Thanks for any and all help!
    Last edited by atomicjoe23; 08-24-2009 at 02:52 AM.
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  8. #8
    Registered cwblair's Avatar
    Join Date
    Jul 2008
    Location
    White Rock
    Posts
    57

    Red face Left Hand Thread

    Yeah, a lot of older vehicles have left hand thread on the driver's side. The old designers felt RH thread might vibrate loose so they went to left hand thread.

    My first Jeep was a 1958 Willys pickup that my neighbour was using as a farm vehicle (i.e. used trees or stumps for brakes). So my first project was to rebuild the brakes so it would stop. Started at the passenger front, then did the passenger rear and I was doing pretty good in terms of time. Then I started with the driver's side rear and what a mess. I had a torch out the try and loosen the "seized" lug nuts, I was even standing on the end of a three foot length of pipe (extension to the tire iron) when my dad casually strolled by and said "You know, the lugs may be left hand thread." I had the wheel off in about 5 minutes after that.

    We definitely need some pics of your project.

    Colin

  9. #9
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default

    Today we got the front and rear axles out from under the frame and finished getting rid of all the surface rust. . .plan for tomorrow is to flip the frame so that we can get rid of the rust on the bottom of the frame. Then we're gonna give it a high-pressure bath to clean out the inside of the frame rails and degrease the frame to get it ready for the Rust Converter, Rust Encapsulator and OD Green paint.

    One things for sure. . .I'm not gonna do a project like this again without a sandblaster. . .they are so much faster and do a way better job with so much less effort, although it's a little hotter being in a blast suit/hood than just a pair of gloves and safety glasses!
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  10. #10
    Registered
    Join Date
    Mar 2001
    Location
    Des Moines, Iowa
    Posts
    338

    Default

    Id reccomend a soda blaster over a sandblaster. Sand will really beat the jeep up where soda is a lot nicer to the metal
    1947 Jeep Willys Pickup

    1959 FC-170

    1971 DJ-5B

    1974 J20

    87 Grand Wagoneer

    01 TJ Sport "Mr Bungle"

    06 Jeep Commander

    1995 Black Grand Cherokee limited 5.2 liter (retired)

    1994 Black YJ (retired)

  11. #11
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Interior Pic's

    OK. . .I uploaded all of the pic's from my computer to Photobucket and hopefully they will load now.

    These are pic's of the interior as it showed up to us (minus all my tools anyway). . .




    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  12. #12
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Deconstruction Day 1

    Here's pic's of the first day of deconstruction. . .when I removed the truck bed, hood, fenders, and grill shell.











    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  13. #13
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Deconstruction Day 1

    And finally here are pic's of the 350SBC installed in the engine bay. . .I'm including a shot of the EZ Wiring 18 circuit wiring harness that came partially installed when we bought the Willy's and a pic of the electric fans installed as pushers.

    . . .I have to upload the rest of the pic's from the last 3 days work from the camera. . .hopefully I'll have them posted up later today and then I'll be posting pic's as I make the progress.







    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  14. #14
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Miscellaneous Pic's

    Here's a couple of miscellaneous pic's as I try to get this thread caught up on pic's. Thought I'd start off with a pic of the Willy's as it came to us.

    Here's the GM Dana 60 front axle, the 14-bolt rear axle, the GM NP205 (10 spline shaft), and the 5-spd. manual transmission we picked up the other day as well as the 40x13.50x17" BFG MTR's mounted on 17" Hummer H2 wheels.

    Also a pic of the 18-circuit aftermarket wiring harness from EZ-Wiring pulled from the engine/chassis to get ready to clean up the frame and the 90's Jeep YJ Wrangler transmission/transfer case crossmember/skidplate that came with the Willy's to be used as it's tranny/t-case crossmember. I had to modify it to fit the TH350 and the Willy's frame.





    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  15. #15
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Deconstruction Day 2 Pic's

    Here are the pic's of the second day of deconstruction. . .this is the day that we pulled the cab off the frame.

    We pulled the engine/tranny/t-case the second day as well.






    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  16. #16
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Deconstructin Day 3 Pic's

    Here's pic's from the third day of stripping the Willy's down. We removed the front and rear axles & leaf springs this day and got the frome up on jack stands to start getting rid of the surface rust.



    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  17. #17
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default Frame and Cab Damage to be repaired.

    Here's a couple of pic's of the damage to the frame and cab that I found.

    I found a small crack in the frame. . .it's on the underside of the passenger side frame rail between the two leaf spring hangers. It goes all the way across the bottom of the rail and approximately an 1/8" into the side of the frame rail. I have already beveled the area with an angle grinder to get it ready to be welded up. I will be boxing this section of the frame on both sides and I will be adding some diamond reinforcement plates here as well.




    The grill shell mounting tab has several cracks in it and the old-school hammered rivets used to hole it in place have stretched so it has quite a bit of play in it which I'm sure is why it developed the cracks. Plan here is to weld the mounting tab to the frame and then to hammer & dolly the split in the side straight and weld it up. . .then I'll weld up the spider cracks around both of the rivets.




    There are only two areas that I found that need addressed on the cab. The first is the cutout in the cab where the brake and gas pedals go through. . .it appears that it was a little out of adjustment and the cab sheetmetal got pushed out repeatedly by the brake pedal lever until it split. I will be hammer & dollying that back straight and then welding it up and grinding it smooth.



    The second are to repair on the cab is the driver's side rear quarter has a dent in the bottom of it. . .just have to straighten that out.




    Really pretty lucky. . .there's some surface rust on the bottom of the cab, but nothing appears to be major. No major pin-holing or rotting out, so no need to weld in patch panels anywhere. . .just get rid of the surface rust and seal it up with some Rust Converter, Rust Encapsulator and then some rubberized undercoating to help with the sound deadening and minimize dents/dings from road & trail debris
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  18. #18
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default

    OK. . .now that the build thread is up to date with pic's I can get back to work on the Willy's!!!

    Let me know if you guys wanna see pictures of anything in particular and I will be happy to take them and post them in the thread. . .if you have any questions about what I've got planned or how I'm gonna do anything, ask away.

    Hope you guys enjoy the project. . .Project Warthog!
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  19. #19
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default

    . . .something funny I hadn't even noticed before is that this engine had two differenct exhaust manifolds on it, a ram's horn style on one side and a log style on the other.



    On the subject of engines. . .which port style is this, round or D-port? They look square to me. . .and I see square port exhaust gaskets in the Jeg's catalog, but the choices in size are either 1.50", 1.63", or 1.94" for the round port and 1.45 x 1.48, 1.45 x 1.55, 1.38 x 1.38, or 1.88 x 1.88 for the square port. I stuck a tape measure up to my ports and they measure roughly 1.25" x 1.25". . I'm getting my parts together and I wanna make sure that I get the right port style exhaust headers and gaskets


    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

  20. #20
    Registered
    Join Date
    Jan 2008
    Location
    Silverdale, WA
    Posts
    271

    Default

    Got the leaf springs and old shocks pulled off the original axles today to get them cleaned up and ready to swap the leafs to the new axles. . .I'm gonna have to disassemble the leaf spring packs first to clean them up, paint them, and put spring liners between the leafs so they aren't trying to flex all rusty. . .

    . . .anybody know where to get the leaf spring pack retainer bands? I know I've seen them somewhere, but now I can't remember where.
    '94 Jeep YJ Wrangler
    4.0L I-6/AX-15 5-spd./NP231
    4WD Hardware 2" Body Lift

    Eventually
    D35 TTB 4WD IFS Conversion w/coilovers & bypasses
    4-link rear w/coilovers and bypasses
    35's

    '49 Jeep Willy's Truck
    350 SBC/TH350/NP205
    14-bolt rear/D60 front, 40" BFG MTR's on H2 8-lugs

Page 1 of 8 1 2 3 4 5 ... LastLast

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Jeep Parts | Jeep Accessories | Trektop NX | Jeep Seat Covers | Jeep Wrangler | Jeep Wrangler Parts | Jeep Wrangler Accessories | Bestop | Jeep Tires | Jeep Stuff | Jeep Wrangler Tires | Jeep Wheels