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View steve392's profile Entries: 226
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03-25-2008 12:56 PM Willys Chassis - Brake Lines
The rear cross-member in this frame is a big obstacle to get around, not only for the exhaust, but for anything else that has to get from one end of the frame to the other. Instead of going around it, I went through it using another thru-frame fitting and routed the brake line in the space between the front 4-link brackets. It's below the bottom link bolt hole, and I know that the suspension will never be adjusted so radically that the link bar will ever get close to the brake line.

Coming out the front side of the cross-member, the line is routed along the frame, jogs around the transmission cross-member and up to the prop valve. I won't be able to route any more of the rear system until the body goes back on, so for now the rear brake plumbing is done.



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  [Entry #61]

03-25-2008 12:54 PM Willys Chassis - Brake Lines
I decided to go with stainless steel brake lines and fittings and here are some of the parts including the tubing, tube nuts, sleeves, fittings and frame clamps. I picked up some plain steel brake line from the local auto supply and practiced my bending and routing using that first. Once I was satisfied with the fit-up, it was duplicated in the stainless tubing.

The line for the rear brakes will come from the master cylinder, through a proportioning valve, down the frame rail and tee off to the left rear caliper before ending at the right rear caliper. Since the master cylinder will be above all of the calipers, there's no need for any residual valves.




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  [Entry #60]

03-25-2008 12:52 PM Willys Chassis - Brake Lines
Now that the exhaust is done, I can start working on the smaller, easier to route plumbing like the brake lines. The first thing to do was to mock-up the e-brake cable. The calipers have an integral e-brake built into them, and are mounted in front of the rear axle. I ended up swapping the calipers side-to-side, and arranging it so that the brake is actuated by pulling the lever on the caliper to the rear. I then looped the cable around the coil-over and then towards the front of the vehicle. The two sides will join at the cable anchor and be actuated by a lever mounted over the driveshaft tunnel. The first two pictures show the layout.
Third picture is a close-up of the flex line between caliper and thru-frame brake fitting. I cycled the rear through it's entire up-down motion to make sure that the flex line would not bind or hit anything. Picture shows suspension fully bottomed-out on bump stop.



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  [Entry #59]

11-30-2007 08:38 AM Willys Chassis - Exhaust System
The chassis as it now sits. I'm glad I decided to have the exhaust professionally done. A great job done by the guys at Posies.


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  [Entry #58]

11-30-2007 08:35 AM Willys Chassis - Exhaust System
Things are very tight, but there's enough room for the shock/rear vertical travel without hitting the exhaust tubing.
I furnished Posies with a template showing the lower body outline of the Willys. The Outlaw frame actually stops short of the body by quite a bit. The exhaust tubing was routed so that it will be parallel to the body underside and it only extends out about an inch past the rear of the body.
The last shot is the crossover. Tight fit, but it was done in such a way that the bottom of the tubing is no lower than either the bellhousing flange or the front frame crossmember.
The crossover is 2" tubing, whereas the rest of the system is 2 1/2".



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  [Entry #57]

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