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| 1956 DJ3A; Resurrection | |
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| Tweet Topic Started: Apr 20 2016, 10:43 PM (2,557 Views) | |
| PapaC | Apr 20 2016, 10:43 PM Post #1 |
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Papac
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I'm now back actively working on my 1956 DJ3A Dispatcher, Convertible Model. Tonight I finished painting the bottom of the tub. Complete passenger side floor, hat channel, and part of the drivers side hat channel has been replaced by metal panels made by me from scratch. Also both front cab mounts have been repaired and any unnecessary holes welded up. |
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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 | Apr 20 2016, 10:54 PM Post #2 |
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Papac
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Here's a few pictures![]() ![]() ![]() ![]() That paint color photographs weird and I don't know a way around that. There are no splotches or noticible runs in the paint. |
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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 | Apr 20 2016, 11:07 PM Post #3 |
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Papac
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Also I can't make the color painted photograph true. The color is Blue Comet Poly Kaiser Willys Code 104A. Paint being used is OMNI'S single stage urethane. Luckily sometimes in the past two years (when I first looked for paint) PPG must have updated their paint codes. This time the body shop was able to pull up and mix the actual color, metal flake and all, without having to scan my paint chips or the original piece of blue I cut out from under the jeep. Two years ago they weren't able to do that so I'm glad I waited. That's 4 coats of color. One light tac coat, two regular coats, and a final coat thinned 'just a little extra, to blend all of the coats together and make that shine come to the top. ![]() ![]() ![]() The metal work is not 100% perfect but I say with confidence that within my skill set I did my best with what I had to work with. |
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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 | Apr 20 2016, 11:15 PM Post #4 |
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Papac
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Tomorrow I'm going to spin it around and try to finish up getting the inside ready to paint. |
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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 | Apr 20 2016, 11:38 PM Post #5 |
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Papac
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Wait. Now I KNOW real willys paint doesn't supposed to have this much shine to it. Especially on the BOTTOM of the jeep. I think I don't care and that I want it to shine. Especially after as much work as I've put into this thing. My reflection in the paint. No flash. Unedited photo. Note the hat channel in the bottom right corner of this photo. (My wife's pink phone!!!)
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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 | Apr 22 2016, 03:10 AM Post #6 |
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Papac
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Previous work included sneaking in a T96 overdrive. I had to make brackets to relocate the clutch control levers and tube because of the solenoid. With my homemade brackets no extra holes had to be drilled in the frame just in case I ever want to change it back. No dj3a dispatchers ever came from the factory with a overdrive installed.![]() ![]() ![]() ![]() Before installing I completely went through everything in and on the transmission and overdrive. It had been stored away and setting idle for over 40 years. I re-used all of the old parts except for the seals and some NOS scyronizers. Also I made all new gaskets. Note that it was SteveK's old muffler that I modified and used. It was handy and solid so I cleaned it up, notched it front and back for extra clearance for the lockout lever (front) and for the emergency brake cable (rear). It looked like it still had some life to it but I poured some powdered zinc in there for extra insurance before installing. |
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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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| SteveK | Apr 22 2016, 06:21 AM Post #7 |
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Looks good. Tight fit, but should be worth the trouble. Thanks for the documentation pics. |
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SteveK 62 Dispatcher South Florida | |
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| PapaC | Apr 28 2016, 12:36 PM Post #8 |
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Papac
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Thanks Steve. As perhaps only you well know it's not exactly a easy mod but I too more than expect it to be well worthwhile. A long week and working nights too to pick up some extra cash temporarily interrupted me REAL work again but there was probably more humidity in the air than I wanted before today so I'm back at it. Here's the first TACK coat on the cab floor and underneath the dash. Of course I'm using my OLD HYLP paint gun. These days that's the only way to go. Note that with that FIRST coat I didn't even try to fully cover the spots. That will come with my additional coats and help prevent runs right off the bat. I'm going to let this dry about a hour, very slightly go over it with 600 grit or steel wool and blow it off and tack it clean between coats. That's one thing I've discovered I really like about the single stage urarthane over acrylic enamel. More shine and easier to paint and work with as I'm finding out. ![]() Now excuse me as I re-tac and clean and get some color on the bottom half!!! |
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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 | Apr 28 2016, 01:01 PM Post #9 |
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Papac
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I probably should have mentioned that even when putting the tac coat on I like to paint crevasse and edges first and let that set a few minutes. There's so many times you have to change your shooting angle that if you don't dust these areas first with paint there are problems that can arise, again runs, dips or get paint too heavy on the sides of them when doing this all at once. Note, I am not and by far not a professional painter, I just know what works for me.
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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 | Apr 28 2016, 01:40 PM Post #10 |
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Papac
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First coat on the bottom. For those of you that might not remember this DJ was a mess when that I purchased it. I'll explain more as we go. This tub had suffered from multiple accidents and the usual rust. Worst thing here the bed floor looked like it had had big rocks or firewood THROWN in it and beat it up bad. The ENTIRE outside of the tub was covered in bondo some of which was up to a inch thick. After probably over a year of body work that is no longer the case. Also note that my entire rear panel had been cut out and was missing. I found some back panel braces on a old tub being advertised on EWILLYS and made a new rear panel to attach it to. ![]() Ps. Now that I've got a first coat of blue on it I see a couple of areas that I think need a little bit of attention. I'll let it dry a little extra and repair, sand, and prime before I proceed to additional color coats. Also noted that the majority of the dings in that tub that wouldn't come out with hammer, dolly, and heat work have been leaded in the old fashioned way instead of using all body filler. |
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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 | Apr 28 2016, 02:28 PM Post #11 |
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Papac
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PREVIOUS WORK. This DJ3A Dispatcher had a way wrong Pinto rear axle underneath it when I purchased. The thing was geared so high that it'd run 30mph in FIRST GEAR. Now with a correct and tagged DJ3A underneath it. ![]() IMPORTANT NOTE. the gas tank is out of a 1963 DJ3A Dispatcher as noted by the gas line outlet is on the top of the tank instead of the front side. I've still got the original '56 tank but as it had been backed into a stump and as yet I've never got it repaired as good as that one. Minor note, since I'm staying with 6v I'm running a dedicated ground for extra insurance on most electrical components for extra insurance. This wire will be mostly hid inside the passenger side frame rail by the time I'm done. Other pictures of previous work ![]() ![]() Homemade rear bumper out of heavier steel. Also I CENTERED it instead of leaving the weird offset to the left. URL=http://s924.photobucket.com/user/ctate1957/media/image_zpsz4hsundb.jpeg.html] [/URL]As you can see I went ahead and wired in a Cole Hershey trailer plug while I had the chance. Had to modify it to fit with it shortened on the inside and the wires running out of each side instead of the back because of the gas tank. |
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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 | Apr 28 2016, 02:53 PM Post #12 |
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Papac
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PREVIOUS WORK Additional dj3A frame photos DJ3A Dispatcher Exhaust pipe routing over rear axle. ![]() Steve helped me out with a bunch of wire, brake line, and gas clips. Unfortunately because of my bigger wires and covering in my very own homemade reproduction wiring harness I had to make slightly larger clips for the wiring itself. I did use Steve's for a pattern here. ![]() LUCKILY when I made my emergency brake cable I made it a litte bit too short. This becomes important in clearing the slightly relocated muffler because of the overdrive. I did need to make a longer rod for the emergency brake equalizer. ![]() ![]() Pretty sure that cable should be galvanized instead of black. Before I put the tub back on I'll take care of small details. That's enough for now, that paint should be dry enough to work on. |
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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 | Apr 28 2016, 06:03 PM Post #13 |
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Papac
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II'm still working inside that tub in real time getting it like I want it for the next coats of paint. In the meantime something is bothering me about this picture.![]() For some reason and I'll have to research again it occurs to me that I've seen somewhere on other non-tailgate, non surrey model DJ3A dispatchers that the bumperettes were flipped upside down to what I've got these. I'll likely have to go through Daves library at Ewillys and search through it closely and look up FBILLS old pictures to see if I can help prove or disprove. I need to find someone who knows, or at least 3 existing examples to see if my theory even holds water before I would even consider taking them back off and turning them over. |
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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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| SteveK | Apr 28 2016, 07:03 PM Post #14 |
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Charles, A quick perusal of all the history pics I have saved, they ALL have the extension on the top side, even some with a tailgate. These pics you are very familiar with too. Look at your favorite Red Dj in Tenn, the turquoise one with the white top and rear seat, and both of the 'ad pics of the lady and tennis guy', and the ad of the Orange Pharmacy Dj hardtop (with tailgate), etc. Sorry, but if you think of it, it would be better to protect the body and not hang up on something...Just my observations. |
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SteveK 62 Dispatcher South Florida | |
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| PapaC | Apr 28 2016, 09:50 PM Post #15 |
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Papac
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Thanks Steve. I KNEW you had a good eye AND could remember things that I sometimes forget. That will save me some time looking it back up so I 'll put it in my agenda to fix that!!! Here's the sanding and minor touch-ups I made on the tub before continuing my painting which I'm working on now.
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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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