Well, I have decided to build another Willys Wagon. I love these vintage old iron classics. This 1962 was completely stock and running when I bought it. But my plans are quite different than stock. This will be a complete restoration from the ground up. But I am not going to run any of the stock drivetrain. The motor, trans, t-case, and axles have all been removed and in its place will be a 1995 5.7L engine, 4L60E 4 speed automatic transmission, and NP241 transfer case from 1995 Chevy Tahoe. In fact, I bought a beautiful Tahoe and stripped it to the bone for everything I thought I might need. I took the air conditioning, cruise, tilt column, power leather seats, drivelines, complete wiring from front to back, interior lights, grab handles, brake and fuel pedal. It is saving me a ton of time and money to go this route. Lots of great parts.

The front axle will be my high pinion Ford Dana 60 from a 92 F350. I narrowed it approximately 8". I installed 4.56 gears, a Detroit locker, 35 spline Superior Evolution chromoly inner and outer axle shafts and Yukon Super Joints. It also has 35 Spline Warn locking hubs. Then I had the 8 lug hubs machined down and redrilled for a 5 on 5 1/2 lug pattern. I installed Ballistic Fab high steer arms and I built a custom tie rod and drag link with 1 1/2" .250 wall tubing and ¾" rod ends. This thing is bomb proof. The rear axle is a Currie Enterprises Ford 9" with 4.56 gears, Detroit locker, 35 spline chromoly axle shafts and a Strange Engineering 3rd member. It has Explorer disc brakes with integrated e-brake.

For the suspension, I am using BDS leaf springs front and rear. Wrangler springs in front and Jeep XJ Cherokee springs in back. They are a perfect fit for the Willys Wagon frame. Although, I had to extend the front frame rails and replace all the spring anchors to accommodate the longer/wider spring. The steering system is an AGR Rock Ram System with the high output pump, new Saginaw box, and hydraulic steering ram. I originally had these axles and steering components on my rock crawler, but decided to transfer everything to the Willys to do something new and different for a while. 

 I bought 35 x 12.50 x 17 Pro Comp Extreme AT tires with Pro Comp 8089 aluminum wheels.

I really like how they look with the frame and body.

I started stripping all the unnecessary brackets off the frame. This took a few days to do, but it came out well.

I made cardboard templates for boxing the frame. Then I began welding together all the pieces that I cut out. I built the primary front frame extension on the bench to ensure that both sides are true. I have only tacked the spring anchors in place until I know exactly where I want them. I am particular about the position of the front tire placement in the fender. Many times I see them too far rearward and it looks terrible. At this point, it is too far forward but I need to wait until I get the weight of the engine, trans, and t-case in the frame to see how things look then. It's a very easy thing to adjust as needed.

Soon ready for motor and power steering brackets.

The frame extensions came out nice. I decided to design a custom shackle to cover the large 3" XJ spring bushing. I sent a .dxf file to a friend of mine to cut out on his computer controlled plaz table. They turned out good.

Next came the attack on the rusted quarter panels and floorboards. This is where things get a little crazy, but it is definitely worth the effort to know all the critical rust is gone.

I just received my new replacement quarter panels, floor braces, and rocker guards from Walck's 4WD. I must say that the craftmanship on the quarter panels is extremely subpar. I spoke with Carl about it and he said there is only one guy making them in the US now and their dies are worn out. Therefore, it causes inconsistencies in the ribs, inset panels, and there are a number of ripples and dents. I didn't anticipate this being the case. I assumed that an advertised quarter panel would be perfect. Very disappointing. I asked him why they simply don't stop selling them or at least tell people ahead of time that they are not great. He said that they sell about 200 of them each year and there are only 3 or 4 guys that call back and complain about the quality. He did admit that he is aware of the problem and has asked the company to fix their dies, but they say it is just too expensive. They won't do it. Well, this means that I will have to do a little more body work than I wanted to, but it won't be that bad. Still worth it to have new sheetmetal. There was so much rust between the the inner and outer panel. I filled a gallon coffee can with it after removing the panel. I am very glad that I removed it. Next is the other side. Before I weld the new panels in place I will have the entire tub soda blasted and sand blasted appropriately. Wish I could afford to have the parts dipped, but that's not going to happen.

30 days later I have it sitting back on the suspension and I got the body back on the frame for the very first mockup. It will be about 4" lower than it is now once I get the drivetrain installed and all the accessories. But for now it gives me some satisfaction to see pretty close how it will look. The front axle is too far forward at this point, but I'll wait to make final adjustments until I get the weight of the motor on it. It is really starting to take shape now.

I am replacing every rubber/weatherstripping component throughout. I will be replacing all the glass as well.

Here is the Chevy Tahoe I bought and drove home. $1500 and in perfect running condition. I felt kind of bad tearing it apart, but not bad enough. It is the perfect donor rig.

A few photos of the cardboard templates I made for rebuilding the floor and firewall.

The motor, trans, and t-case are in now. Looks great and everything fits very nicely. I took a lot of time to carefully cut out the original firewall, floor, and kick panels. I kept the original front body mounts to ensure alignment and cutting out everything around it will allow me to sand blast in all the secret places.

Here is a shot of all the wiring I pulled from the Tahoe and one of the leather seats.

Each time I accomplish something major, I like to take a photo as I walk into the house for the night. Here are a few I took from various stages.

I got the Flowmaster exhaust completed except for two straight 4' pieces I need to pick up from the exhaust shop. I mounted the AGR steering box and I am super excited about getting creative with the Grant steering wheel. I was able to use the original Willys horn button with the Grant horn mechanism. So, I have a horn and the two go well together. And here is a shot of my little helper, Jasper the friendly mocha ghost... The coolest dog ever.

More to come soon. Keep watching...