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11-19-2009 02:12 PM Willys Interior - Heat & A/C
The first picture shows the finished support brace between the body and the dash support. It stiffened up the support considerably, and does not get in the way of the a/c unit or defrost and a/c ductwork.
The second photo shows the completed a/c unit installation. The center "duct" for the a/c is just a turn-down supplied by Vintage air. I have room to get the two end outlets fit up with flex ducting, but had nowhere to go with the center one. This turn-down will blow the cool air straight down towards the floor. I may be able to add some flex duct to the turn-down if I cut it back a bit, but am undecided at this point.
The third photo is another view of the completed under-dash area. In moving the dash support rearward by an inch, the dashboard itself will also move rearward by the same amount. This is okay as it will give me a little more room for the defrost ducting. It will also help the gauges in clearing the master cylinders. Also seen is my column drop and windshield wiper setup which I'll cover in separate journal entries.


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  [Entry #99]

11-19-2009 01:55 PM Willys Interior - Heat & A/C
I'm using a Vintage Air heat/air unit that will be mounted behind the dash in the more or less usual spot. Outlaw provides a 3/4" square steel support bar that runs horizontally across just behind the dashboard. It ties together the door posts side-to-side and is also has mounting brackets on each end where the dash attaches. This is also the only steel bracing that is available for the top steering column support.
In fitting up the a/c unit, the bar got in the way, so I cut it out and moved it rearward by an inch, giving enough room for the Vintage Air Unit.
The first pic shows the support bar being relocated prior to welding back in.
Once the bar was repositioned, I installed the a/c unit and fabricated two clips to support the front of the unit, which will be welded to the support bar. The back side of the a/c unit is supported by a vertical bracket that I welded to the previously made firewall framework.
Second pic shows the a/c unit fit into place with the new front brackets.
The third picture shows the rear support for the a/c unit. It also doubles as part of the bracketry for the wiper motor. Above that in the photo is another plywood support that I attached to the body just under the windshield frame area. With the weight of the a/c unit and also the stress of the steering column on it, the 3/4" steel support bar needed to be stiffened up. The picture shows the top mounting point for a brace that will run from the body to the top of the bar. It was epoxied and 'glassed in place.


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  [Entry #98]

11-19-2009 11:01 AM Willys Interior - Brake/Clutch Plumbing
Here's the finished Brake & Clutch master cylinder assembly all put together and installed, along with pedals and steering column.


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  [Entry #97]

11-19-2009 10:58 AM Willys Interior - Brake/Clutch Plumbing
The hard line from the brake m/c's is 3/16" s.s. with -3AN fittings, which is the same as the rest of the brake line plumbing. Since I didn't want to make a mistake bending the stainless tubing, I used some inexpensive steel brake tubing to first plan out and bend into shape. Once I was satisfied with the routing and dimensions, I duplicated the line in stainless. The lines were routed down under the m/c's and away from the pedals over to the bulkhead fittings.
First two photos are tube bending in progress, and the last photo is the finished result with the two brake hard lines and the clutch flex line.


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  [Entry #96]

11-19-2009 10:49 AM Willys Interior - Brake/Clutch Plumbing
Since the master cylinders are the remote type, I picked this remote reservoir unit, also from Kugel. I mounted it to the firewall in a location high enough that would ensure gravity flow from the reservoir to the m/c inlet, but still give me hood clearance.
I decided to use some -4AN flex brake line from the reservoir
outlets to the m/c inlets. Kugel had supplied some rubber hose and plastic fittings for the purpose, but I elected to go this way instead. More leak-free in my opinion.
First pic shows the reservoir mounted to the firewall.
Second pic shows lines from reservoir to m/c inlets.
Third pic shows the bulkhead fittings I am using at the firewall. I thought that this would be the cleanest way to transfer from the inside of the vehicle to the outside. I will be using hard line from the m/c outlets to the brakes, and flex line for the clutch.


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  [Entry #95]

Pages (41): 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 [22] 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41


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