Would have been nice to be able to leave it in the 'package' as it sits here but unfortunately the axle centreline is too far back for the Willys. I will leave all the suspension, diff, steering, swaybar etc connected to the engine cradle and just make new engine mounts to attach to the same frame further back. Will have to over come some things like the oil filter than getting in the way then, but will work something out. You can see also that I have carefully removed the front coil over and upper wishbone mounts from the Grand to reuse on the Willys frame along with the inner mounting points from inside the Grands frame. The Willys frame will be re-contoured to follow the exact outer dimensions of the Grand so these mounts and others will be in the same place.
I have kept the rear quarter panels intact as not a mark on them and hoping they can be sold off at some point along with much interior panels etc from the rear of the Grand.
I made myself up a bit of a rotisserie from two cheap engine stands that I made higher. These were rated at 560 kg each so should be more than enough for what I am using them for and for under $100 together. Much friendlier on my back when you work alone and have to flip it often. I will be using the firewall and floor as well as will give me all the seats mounts along with heater, A/C, steering column, console, hand brake, lower dash, pedals etc. mounting points as well. So I decided now was a good time to straighten the damaged firewall from the sideways impact it had. You can see the gap behind the ruler that has to be removed.
Looking much straighter now and even a bit flatter than the undamaged side! Some more work will be done later on the upper section once removed from the frame rails. Can continue on now to remove the hundreds of spot welds holding the Grands frame to the floor. A lot of work and only drilling through the frame layer and not the floor pressing to reduce the amount of holes that need welding up afterwards.
Well after 400 odd spot welds drilled out, the firewall and floor is finally free from the uni-body frame. I have cut the floor long so I can make any adjustments for cab length later. I cut it just before it steps up under the rear seat area.
Also done a mock up at the lowest I can get the suspension and not hit the underside of the front guard with the upper wishbone at full compression. This also includes lowered coils and still have enough up travel for a comfortable ride. I tested this out by dropping the whole front of the Grand from the crane when still assembled to see how far it compressed. Short video of it here. Tried a few different tyre heights and will go for 32" ones shown or maybe slightly higher. I have cut and pasted some wheels I am thinking of using in 20" as don't want shiny bling wheels on this. But found out I couldn't get any tyres in the height and narrow width I am after so that idea is out for now. Thinking it might be better to go for more of a hotrod feel in some steelies in the 17" which is the smallest rim I can go with the Grands large brakes. The right picture also shows the cabin stretch of 5.5" that I plan to do, or very close to it, also. This is the same proportion the cab is being made wider and gives me much needed interior leg room I need for my 6'2" frame.
The next chapter has begun. I drove in the Grand Cherokee and carried it out! So now the Willys is back in the workshop ready for the tear down after much time was spent calculating how all the driveline would fit the frame. Hard to believe in the left shot above that the Hemi and all the suspension etc will one day be under the Willys. The rear bed has been removed and the guards and lower frame shirt saved for reuse. Nothing else will be used as in too poor a condition and not the bed style I want as want the US version as fitted to these over there.
Front panels all off as was surprised how easily they all unbolted. Even the doors which are held in with just screws, that everyone else seems to strip, came right out. Hoping it would because I sprayed all the bolts with WD40 every month for the last year.
Winched the cab off so I can have a bare frame to work on.
Removed all the cross members and gave the rails a good clean. They are in excellent condition considering their age. Next thing will be to weld up all the rivet holes that held in the cross members and fully box them for extra strength as too flexible stock and have to be made to handle the torque and weight of the V8 as well.
Gives you a better idea of the engine cradle that holds everything under the uni-bodied Grand Cherokee. Just held in place with four big bolts. I will be doing the same so I can bolt it under the Willys frame. Paint damage in the front corner is from the battery acid leaking on to it. I will make my new engine mounts once I move them 175mm back on this frame to centre the axle under the wheel arch. As the frame drops away steeply, cant just weld the old brackets back in place.
Before I removed the engine mounts, I made up this little jig to make it easier to setup the new ones. They tilt 5.5 degrees back and are different heights left to right to match the mounts on the block, so felt this was the way to go. Removed the engine mounts and mocked up the front cradle 175 mm further forward than it was before. The oil filter used to angle forward at 45* and would have ended up on top of the steering rack. I removed the mount and screwed the filter directly onto the block so it pointed straight down and it cleared the steering rack easily.
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