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Aluminum 1940 Willys Build

Discussion in 'The Hokey Ass Message Board' started by Salt Flats Speed Shop, Mar 27, 2008.

  1. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    This is the project that started everything.

    First I started making the frame. I used an origional frame for measurements, but I narrowed the rear end to allow 20" wide tires in the back.

    Its got a mustang II front suspension and will have a narrowed 9'' with a 4-link.
     

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  2. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    This is the origional 40' willys coupe that I used for all my patterns and measurements. Its in pretty nice shape!
     

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  3. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    First I had to make a fixture inside the origional coupe so that I could have something to hold the door jams in the air.
     

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  4. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Next I started making the panels starting with the quaters, and working into the roof.

    Each panel was checked against the origional car to for perfect fit.
     

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  5. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Next I started on the panels from the trunk down.

    I made the lower panel in 3 sections like the origional, but I decided to change it to one panel later.
     

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  6. N312RB
    Joined: Dec 12, 2007
    Posts: 418

    N312RB
    Member
    from Burlington

    SICK!!!! i love it...keep updating please :D
     
  7. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Next came the roof.

    What a huge panel to make... that was crazy
     

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  8. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Next was the windshield area.

    This was very tricky to make and keep flat.
     

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  9. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Next were the fenders, front and rear.

    I made these durring my christmas brake (merry christmas to me:)
     

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  10. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Next I started making the inner doors.

    I want these to be pretty much like the origionals. I loved the ribbs in the lower part, and insted of making some flat inner door this will look tons better. Expecialy where I am going to keep the whole car in bare aluminum I want everything to look perfect.
     

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  11. haroldd1963
    Joined: Oct 15, 2007
    Posts: 1,154

    haroldd1963
    ALLIANCE MEMBER
    from Peru, IL

    Wow!!! I wish I had the time and money to invest in the tools and training do what you have done.
     
  12. GizmoJoe
    Joined: Jul 18, 2007
    Posts: 1,296

    GizmoJoe
    Member

    Ok.
    Looks like another one of them-thar talented people!
    Amazing work.
     
  13. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Next I got the fenders on and built a hood.

    The hood was another tricky part to make. It has a slight bend in the center that starts from the front of the nose, and then dissapears in the back.
     

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  14. a.d.-hawk
    Joined: Oct 4, 2006
    Posts: 17

    a.d.-hawk
    Member
    from Omaha, Ne.

  15. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Back to the door.

    The bead was made in a pullmax with some dies that I made to reproduce the door bead.
     

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  16. Slag Kustom
    Joined: May 10, 2004
    Posts: 4,312

    Slag Kustom
    Member

    very nice work.
     
  17. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Next I started metal finishing the fenders.

    Then I narrow a 9", and got wheels on the car. I want to be able to fit 20" wide tires in this so I narrowed the rear end 18".

    Next I started rolling the trunk skin, and made the rear windows.

    I used the origional cars back windows as a form to make mine on.
     

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  18. Nice work but you sound like a telemarketer that just dove into his script and wants to get it all out before you hang up.
     
  19. buckeye_01
    Joined: Jun 20, 2005
    Posts: 1,441

    buckeye_01
    Member

    That's a piece of art! Nice work!
     
  20. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    I had the willys in the utah autorama. I did metal shaping demonstrations all 3 days....I was exausted. I demonstrated using the english wheel in making a section of the rear fender.

    I won sponsers choice.
     

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  21. 55chieftain
    Joined: May 29, 2007
    Posts: 2,162

    55chieftain
    Member

    Damn, nice work!
     
  22. Salt Flats Speed Shop
    Joined: Sep 30, 2007
    Posts: 1,472

    Salt Flats Speed Shop
    Member
    from Utah

    Back to the doors. I used a stock door to form the aluminum around. Worked pretty slick.

    This is pretty much where the car is today. Probably not enough info for what took me 9 months so far.

    Now i have the shop open I havent had much chance to work on the willys. Once I finish the 32' shop truck i'll get back on the willys. But for now she sits...although its allways fun to see her every morning:)
     

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  23. Fishtail8
    Joined: Jul 18, 2007
    Posts: 366

    Fishtail8
    Member

    That is impressive.... Nice work...!
     
  24. Nice work man! Is that you holding the trophy???
     
  25. Janne
    Joined: Jan 12, 2004
    Posts: 1,174

    Janne
    Member

  26. panhead_pete
    Joined: Feb 22, 2006
    Posts: 2,290

    panhead_pete
    ALLIANCE MEMBER

    OMG - Thats incredible. Thanks for posting.
     
  27. Topless Ford
    Joined: Feb 10, 2007
    Posts: 560

    Topless Ford
    Member

    Been needing an aluminum front end for that Galaxie...............:eek:

    Awesome work, keep it up. The world needs more Willys'.
     
  28. captainjunk#2
    Joined: Mar 13, 2008
    Posts: 4,330

    captainjunk#2
    Member

    outstanding job on your willys a work of art
     
  29. You are a friggin' sheet metal genius ... !!
     
  30. oldandkrusty
    Joined: Oct 8, 2002
    Posts: 2,077

    oldandkrusty
    Member

    You have got to be shitting me! Nine months to go from nothing to essentailly a rolling full bodied all aluminum car!!! I feel so freaking inferior.

    Beautiful, just simply beautiful. I don't blame you for feeling good every morning when you get to see her.
     

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