Aluminum 1940 Willys Build

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.

 

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

 

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.

 

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.

 

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.

 

SICK!!!! i love it...keep updating please

 

Next came the roof.

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

 

Next was the windshield area.

This was very tricky to make and keep flat.

 

Next were the fenders, front and rear.

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

 

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.

 

Wow!!! I wish I had the time and money to invest in the tools and training do what you have done.

 

Ok.
Looks like another one of them-thar talented people!
Amazing work.

 

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.

 

Awesome....

 

Back to the door.

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

 

very nice work.

 

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.

 

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.

 

That's a piece of art! Nice work!

 

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.

 

Damn, nice work!

 

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

 

That is impressive.... Nice work...!

 

Nice work man! Is that you holding the trophy???

 

Impressive!
Have you seen these?
http://lazze.se/photoalbum.php?catidx=8
http://lazze.se/photoalbum.php?catidx=9
http://lazze.se/photoalbum.php?catidx=10
http://lazze.se/photoalbum.php?catidx=11
http://lazze.se/photoalbum.php?catidx=12

 

OMG - Thats incredible. Thanks for posting.

 

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

Awesome work, keep it up. The world needs more Willys'.

 

outstanding job on your willys a work of art

 

You are a friggin' sheet metal genius ... !!

 

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.