WILLYS STATION WAGON.
One of our long-term restoration projects. A rare post war classic.
When the chassis returned from the blasters, it was prepared and ready for painting. Firstly, we started with a coat of epoxy primer, then prepared, and coats of 2K paint were applied. We then moved on to the axles, which were stripped down and cleaned, ready for painting. After assessing what was required, a parts list was drawn up and placed with suppliers in the States. Once the Jeep was cleaned and inspected, the axles were painted and ready to fit the new parts.
rThe shell was then stripped down and sandblasted. The panels returned from the blasters, and we started by reconstructing the doors. The bonnet was next to receive attention, with rotten areas removed and new sections fabricated and welded in. The tailgate upper section was next, with corroded areas removed and sections fabricated and welded in. The shell returned from the blasters and was immediately sprayed with epoxy primer. We then started the welding work, eliminating areas of rot and replacing them with fabricated sections. Areas of the inner sections of the roof around the rear tailgate top hinge were removed, and a new section was fabricated and welded in for strength.
Next, we moved on to the rear floor. A rotten section was cut out, and a new section was fabricated. The replacement engine, gearbox and transfer box were then trial-fitted. Modification work was required for the chassis, moving engine mounts, and fabrication of new crossmembers. The front axle was assembled and fitted, and the front end was refitted to check for clearances. The rear axle was then trial-fitted. The near-side rear quarter panel and floor sections were then removed and replaced. Work started by eliminating the rotten areas around the B post to sill, fabricating new sections and welding them in. The rear arch and floor had sections fabricated and welded in. Once the work on the interior area was done, we fitted the new rear quarter panel, carried out the metal finishing, and coated it with primer for protection.
Our attention then moved to reconstructing the floor, sill sections and B post, fabricating panel repair sections, cleaning and rust-treating areas and welding the repair sections into place. We then ribbed the rear floor section, replaced the doors and modified them to take door locks and handles. The body was then in the filler stage. Front wings A posts and sill sections were next on the list; areas were cut-out sections fabricated and welded in. A new rear quarter panel was welded in on the opposite side of the vehicle after we repaired the inner sill and fit a rear floor section. We then moved on to fabricating panels for the bulkhead and front floors.
We had to modify the doors and pillars to take door handles and catches and finish all welding repairs. Afterwards, we proceeded to trial-fit panels, fill the body, and do filler work on the inside panels. Additionally, we had to fit seat belt anchor points, remove the body from the chassis, and make a frame for it. Everything was prepped and primed inside, and we applied spray filler to the body. We then proceeded to mock up new front and rear brakes, fit road springs, fuel lines and brake lines, mock up the clutch for clearance and setting, and fit the gearbox and driveshafts. We then made up a bespoke tow bar and frame, applied Raptor to the underside, blocked down spray filler and applied primer to the outside. We assembled the new pedal bracket, fitted the new brake servo, and built up the mechanical and electrical components.
We are now doing a trial assembly. We have fabricated a new battery tray supports and a bespoke stainless steel exhaust system.
We have now completed bodywork to the shell and have seam sealed and applied a RAPTOR underbody treatment. Attention has moved to getting the inside of the vehicle painted in the chosen body colour.
The chassis and body are now mated back together and we work on the mechanicals building sub assemblies and fitting them to the vehicle. Sound deadening is applied to the inside of the vehicle before we start on fitting a new wiring loom.
The loom is now labelled and run trough the vehicle to all the relevant sites of the electrical components. Front lights are trial fitted, rear lights are made up as the request was to use something different to the original, these now incorporate stop and tail and small indicators all in LED. Fabrication also starts on some bespoke dash panels to hold the gauges, finished to be finalised but maybe brushed.
Panels now move to the booth again after having primer applied to the inside on the first visit we now have prepared the outside and apply primer to the exterior. Window trims etc are then sent to the booth to have colour applied. Next into the booth are the tailgate and the bonnet to have colour applied to the inside. Next the shell goes back in the booth and we prime and paint the roof. The shell is next to visit the booth to have its top coat and laquer applied and splendid it looks in”firecracker red”. Next we will prepare the bolt on wings with a view to get them painted. The bulk of the panels now get painted with just the bonnet and the tailgates left to do.
Click below to take a closer look at this project.
