1962 Jeep Willys Build

Glad to read the rebuild resolved your fuel issue.

 

Hoping to install the ballast resistor and the new distributor tonight. If all goes well i can tackle the new muffler install as well. Im not holding out hope for getting those old nuts off the manifold flange studs. Been soaking them the past few days in P.B. blaster. Praying i dont have to buy a new manifold

 

Short of buying a new manifold, what are my options? PO welded the nut to the flange...

 

Problem solved. I ordered a new manifold.
But now my other problem. One that I can't fix off the top of my head. These two bolt heads snapped off. It's the top Center one and the right one closest to the firewall.

 

On a positive note they aren’t broke off flush. Drive a nut onto the stud and weld it on. Then use your favorite method for removing tight bolts.

 

I weld a washer then a bit mash some canning wax into the stud while it’s hot wait a little and wind it out. Lacking canning wax use a crayon.

 

I had the same two freeze. I did get the top one out but had to cut, drill, tap the rear.

 

x2....

 

I easy out them with heat. Usually grind them flay and center punch and drill them out. Takes a little time, but if you progress through the drill sizes and get down to just a little thread left, they spin right out. Just did it on my F Head, the distributor hold down bolt snapped off. Good luck.

 

Almost ready to install this! My other jeep needs some attention...but its registered and almost ready for the maiden voyage!

 

Done...new muffler..check

I used an oxy/map gas torch to get the embers glowing hot, and then I tried to turn the studs out with a vice grips. no luck. then I tried to weld a nut to the stud. no go. the nut kept breaking off the weld. or the stud would break farther down the shaft. I ended up just building up gobs of weld on the stud shaft itself and using it as the "nut". then, with a little finesse of the vice grips and a lot of muscle power combined with a steady stream of curses, I managed to turn them out. I ran a tap through the hole to clean it up for insertion of the new bolt.

the 2 studs that broke are actually in the water jacket, and I think that is the reason these two bolts were stuck and broke.

while I got the new muffler on, I bumped the old fuel pump, which disturbed the gasket. so when I went to start it up, fuel was spraying everywhere. now I need to add fuel pump gasket to the list of things to get ASAFP. maybe by next winter she will be road worthy.

 

Idk what it sounded like before but you will enjoy the quiet when you're done. Putt putt putt....

 

just ordered the fel-pro 5019 fuel pump gasket. hopefully I can come home next week to it sitting in the mailbox or on the front porch.

 

Granted, im not a shipping magnate, but REALLY?!!

 

Spent two hours fabbing a battery mount on the firewall. Once it was done to my satisfaction and mounted in the right place I decided to take apart the previous owners disgusting work of sheets of Steel and plywood sandwich together. To my surprise there was a brand new original battery tray under all that crap. lesson learned.

 

all right, updated checked off "to do list"
1. muffler system. the muffler is done, I picked up an International Harvester muffler to replace the muffler that came in the kit. the wife wanted straight pipes, I detest loud vehicles, so we compromised. it sounds good when you step on it.
2. battery is properly mounted
3. fuel pump gasket has been replaced, no more leaks
4. installed the electronic distributor and a new ballast resistor last night.

tonight's list entails:
1. install new plugs/wires
2. replace the coil. while hooking up the electronic distributor I noticed a large bulge in the coil. when I touched it the cap popped off and the oil was leaking out. this cant be good, right? so ive got a coil to pick up on the way home tonight.
3. check and ensure timing is right since its all new ignition systems throughout.
4. cut out the sidewall of a tractor tire for the body to frame bushing mounts. I was going to use some 1" spacers I had made from some thick rubber we have at work, but decided against that.
5. test drive it on the trails at my house after its all said and done tonight.

 

jeep is almost all ready mechanically. motor purrs like a kitten, the muffler is as loud as a tractor, and its reliable as all get out now.

I am going to redo the brakes this week/weekend. going to put on 10" drums on the front and also all new wheel cylinders as well. a 10" drum is 50 bucks at a FLAPS, and 18 bucks on rock auto. hard to compete with that price difference. I was going to do the disk brake conversion on the front, but I will wait till winter to do it. I just want the wife to be able to drive it safely to and from work this summer.

 

Nice build thread, where did you source your floor pans from ?

 

Rock auto