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Various DJ Parts Restorations ; intertwined with Off Topic
Topic Started: Jan 19 2014, 01:23 AM (16,086 Views)
PapaC
Papac
[ *   *   *   *   *  ]
F Bill,Mar 5 2014
05:33 PM
Is there a replacement hat channel set that is correct for a DJ3A? I haven't actually measured them but they look taller than the Cj2A /3A ones....At least the ones in my DJ with doors are weird looking to me compared to a 2A set..

Glad I didn't buy the ebay hat channel now!

At the very least it would have been missing the extra piece that supports the leg on the passenger seat. Guessing that would be another way to accurately identify a dj tub, IF, the whole floor hasn't been replaced .

I hope this evening to go over that side again with a shrinking disc and smooth it up just a little bit better.

As soon as I get my frame turned over I hope to make a giant cardboard template so I can accurately locate the missing holes and nuts.
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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F Bill
Jeep discovery and aquisition specialist
[ *   *   *   *   *  ]
If it is still a bare frame just place it in position on the upside down tub. Best template you would ever have!
59 convertible 15933 needs drivetrain
60 convertible 17052 has a V6 and 4WD
60 Surrey 17509 went thru Katrina and looks it.
60 Surrey 17918 started it all...Toyota axle, BW
Wrecked Surrey Tub with fenders and grille
56 tub, from 11826
And a couple parts DJ's with no ID left.
All my jeeps are projects....only runner is my
DJ with doors..
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PapaC
Papac
[ *   *   *   *   *  ]
I still can't believe how good this works


Highs marked with chalk for effect


(underneath bed floor on tub)


Posted Image



Posted Image






Posted Image
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
Offline Profile Quote Post Goto Top
 
F Bill
Jeep discovery and aquisition specialist
[ *   *   *   *   *  ]
Did you do anything to the edge of the disc to make it less apt to dig into knuckles and your project? The pics make it appear you have tried to turn the edge back a little...The original shrinking discs were serrated and very hazardous to skin. Gloves are a great idea anyhow.

I never thought of using a saw blade.. I think it is thicker than the usual shrinking discs you buy.....but dull saw blades are a dime a dozen especially around my house... (Why yes, I cut firewood with a skil saw...and often my firewood has nails in it. .) so I am watching with much interest.

I used a shrinking disc one time at a metal shaping gathering.. It was like magic. I have torch shrunk for years, and it is tough to do controllably. The disc is so much better, especially in the hands of a part timer.
59 convertible 15933 needs drivetrain
60 convertible 17052 has a V6 and 4WD
60 Surrey 17509 went thru Katrina and looks it.
60 Surrey 17918 started it all...Toyota axle, BW
Wrecked Surrey Tub with fenders and grille
56 tub, from 11826
And a couple parts DJ's with no ID left.
All my jeeps are projects....only runner is my
DJ with doors..
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F Bill
Jeep discovery and aquisition specialist
[ *   *   *   *   *  ]
I don't remember the one I used being that loud. But it was more flexible too. It was almost like using a worn out sanding disc.

I had heard about shrinking discs for years and thought they were some sort of gimmick.. Boy was I wrong.

You have to be getting quite a workout with that old grinder running it. Can you say HEAVY!!
59 convertible 15933 needs drivetrain
60 convertible 17052 has a V6 and 4WD
60 Surrey 17509 went thru Katrina and looks it.
60 Surrey 17918 started it all...Toyota axle, BW
Wrecked Surrey Tub with fenders and grille
56 tub, from 11826
And a couple parts DJ's with no ID left.
All my jeeps are projects....only runner is my
DJ with doors..
Offline Profile Quote Post Goto Top
 
PapaC
Papac
[ *   *   *   *   *  ]
Yup. HEAVY....and then some.....and I thought it was a GIMMICK idea too!!!


I didn't know they were 'supposed' to be flexible, never had my hands on a real one
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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F Bill
Jeep discovery and aquisition specialist
[ *   *   *   *   *  ]
Yes, I wouldn't say floppy flexible.....but they give a tiny bit. I've seen guy s make them from stainless pot lids too. The commercial ones have a very smooth edge that doesn't vibrate as it hits the metal like an uneven edge would, which I think is why they are quieter. But, the more noise, the more that is being accomplished, maybe.

You'd enjoy a trip over to the Metal Meet or All Metalshaping forums to check out the shrinking disc threads.....You'd probably get lost reading the whole site, it is like a candy store over there seeing what guys can do with mere sheet metal.
59 convertible 15933 needs drivetrain
60 convertible 17052 has a V6 and 4WD
60 Surrey 17509 went thru Katrina and looks it.
60 Surrey 17918 started it all...Toyota axle, BW
Wrecked Surrey Tub with fenders and grille
56 tub, from 11826
And a couple parts DJ's with no ID left.
All my jeeps are projects....only runner is my
DJ with doors..
Offline Profile Quote Post Goto Top
 
F Bill
Jeep discovery and aquisition specialist
[ *   *   *   *   *  ]
The easier way to do that top is something called metal spinning. Might need an alternate material to do it easily, but here is a thread where a guy did a continental kit for a trailer:

http://allmetalshaping.com/showthread.php?t=1880

You may have to join up there to see it but it is worth joining. Lots of great info for guys who make entire fenders for Jaguars before lunch. (well maybe not quite that fast..)

I think you call that LATH metal, not lathe... but like Charles I call it expanded metal as well. Probably the easiest part of your filter to source.

Womenfolk as tv repair MEN? Hmm.. I wonder how they'd do on bike and tub repairs.. I have a few projects if they get too bored at your house. :D

Have fun with the grandkids!
59 convertible 15933 needs drivetrain
60 convertible 17052 has a V6 and 4WD
60 Surrey 17509 went thru Katrina and looks it.
60 Surrey 17918 started it all...Toyota axle, BW
Wrecked Surrey Tub with fenders and grille
56 tub, from 11826
And a couple parts DJ's with no ID left.
All my jeeps are projects....only runner is my
DJ with doors..
Offline Profile Quote Post Goto Top
 
PapaC
Papac
[ *   *   *   *   *  ]
Fresh stripped as shown in previous post


Posted Image


Two hours in (working both housings multiple times from both top and underneath)

Posted Image
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
Offline Profile Quote Post Goto Top
 
PapaC
Papac
[ *   *   *   *   *  ]
Just about gettipng that wheel well pretty slick. If you can look past the stains that is. I think that you can notice that the light is finally starting to actually show that the metal work is getting pretty close .



Posted Image


Posted Image


Posted Image


I keep forgetting stuff that I should be remembering...I'll show one example my next post. I HATE it when I forget or lose track of tips and tricks and add unnecessary time and labor to this project !!

Today I also went over the bed floor itself, both top and bottom, crisping up the edges of the channels.

Here's the other wheel well housing housing. I still like a little bit on getting it straight and smooth.


Posted Image
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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PapaC
Papac
[ *   *   *   *   *  ]
Pinpointing more areas that still need adjusting

Posted Image

Setting up so I can isolate heat right on the ridge for shrinking


Posted Image


Using a big washer so I can isolate heat in this tiny depression for shrinking

Posted Image

Starting the lead work

Posted Image
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
Offline Profile Quote Post Goto Top
 
SteveK
Member
[ *   *   *   *   *  ]
PapaC, I'm amazed at your repertoire of skills, knowledge of chemistry, resources, and patience as well as determination.

When you described the 'dropping of lead' and the 'blob', it reminded me of something, and maybe the air between during the drop is causing your 'blob' from cooling some before contact???

FYI, (and I don't know squat and ZERO experience about any of this, just passing on info for consideration), I saw a guy doing lead, even vertically, and his technique was heating the surface and washing or dragging the lead bar over the surface, repeating it til he was satisfied of the buildup. It didn't seem to be prone to breaking loose the bond at all. The heat was in very short spurts directly on the surface once he began with the lead. It didn't leave him with the splatter pieces of 'cold solder' around the surface, just solid waves all bonded. On the verticals, all of his strokes were bottom upward, dragging the flow.

Hope this tidbit helps you. What a 'learning' and 'thought provoking' series your project has become!!! Thanks for your details and pics.



SteveK
62 Dispatcher
South Florida
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F Bill
Jeep discovery and aquisition specialist
[ *   *   *   *   *  ]
Are you using wooden paddles and beeswax to lube them?

For those rounded ribs I think finding a file that will work is going to be tough. They used to make reveal files that were custom made in the shape of the body lines but they are pretty hard to find nowadays.

Now if the next time we see your DJ it is a lowrider we will know you applied slightly too much lead. :P

Excellent work, keep it up!
59 convertible 15933 needs drivetrain
60 convertible 17052 has a V6 and 4WD
60 Surrey 17509 went thru Katrina and looks it.
60 Surrey 17918 started it all...Toyota axle, BW
Wrecked Surrey Tub with fenders and grille
56 tub, from 11826
And a couple parts DJ's with no ID left.
All my jeeps are projects....only runner is my
DJ with doors..
Offline Profile Quote Post Goto Top
 
PapaC
Papac
[ *   *   *   *   *  ]
I got something amazing in the mail yesterday.

My extra 1956 dj dash panel came in along with its complete instruments, switches, and under dash wiring harness including some of the leads all the way to the motor and at least remants of marked pig tails that go every where else!!!

AND along with it was all of the braces for the back panel and a bonus.

A complete dj carbureator that I needed to complete my extra dj motor someday!!!


Waaaaaa Hoooooo!!!!
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
Offline Profile Quote Post Goto Top
 
PapaC
Papac
[ *   *   *   *   *  ]
FINALLY chemically treated and ready for primer

(the beeswax and paddles made all the difference)

Posted Image

First coat of primer (self etching)

Posted Image

Thinking now a few coats of sand able primer and block sanding now and then ought to make it look real pretty......and NO BONDO!!!!


Also I got the leading work. 90% done on the other side. Hope to finish that sometimes tomorrow and get started on the bed floor, which is already in pretty good shape by now and should go fairly quick.
Charles Tate....North Mississippi

1956 WILLYS DJ3A Convertible
Doing ground up nuts and bolt restoration by almost entirely reconditioning original used or a few NOS DJ3A parts.

1962 WILLYS DJ3A Convertible. (For research and parts only)
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