[94yjstocklook]

Originally Posted by 50wllystrk

Your thinking is exactly where I am, I do have the extra threading on the u-bolts so the fit is perfect. My main concern is the tabs/holes bending again after years of service as the old ones did. The clovers will spread the load of the clamping force across a much larger area and should solve the problem for years to come.

The bottom plate is the next set of pictures. Now that the first clover is drilled exactly how I want I am gonna use it to align the next 3 sets of holes I need to drill and figure a nice smooth way to create the kick-ups at the ends of the bottom plates. Follow along, I think I'll present an alternative to how most would bend up the edges.

You always keep me wondering whats next. I hate the way u ended this post. It is like when tv shows quit right before you find out what is gonna happen keep up the good work

[50wllystrk]

Alright, alright, a simple request, I will honor it. Let's kill the suspence and I'll work backwards then. Two pictures of the final product. I gotta tell ya, I find then to be very appealing to the eye, and you get the feeling of the strength the clover will provide. Hmmmm, clover, never thought I'd use the name in building suspension parts.. Nobody get excited about the u-bolt not being straight up in the second picture, I was just going for the picture, I didn't slide it up against the spring perch.
I kinda see 1/8, 3/16, and 1/4 inch and beyond in different classes to work with. 1/8 inch... pretty manipulative, with no heat it's fairly cooperative to bend and shape. 3/16, you can work with it but you'll need heat sometimes to reshape it. 1/4 inch, big hammer, torch, leverage, ect. I'll bend the 1/4 without hammer, torch or leverage.
Also, I've taken a couple pics of the tools to work these pieces. I talked to a fellow in town the other day about some welding and grinding on his bumper. I found that I took for granted that he would know the tools and grinding discs, but he looked a little puzzled. So during the fabrication on these plates I took a couple pics of some tools also. Ok, finished product, no more suspence.

[Deuskid]

a pure example of form following function

[J-Quad]

50wllystrk,

YOUR FABRICATION SKILLS ARE AWESOME, MY FRIEND!

It's hard for me to tell from your pics, but it looks as though you may have used extra long nuts on your U-bolts, did you?

It also looks like lock washers as well?

Will you use any anti-seize on the U-bolt threads during the final assembly?

By-the-way, are you still planning to add a cross strap to the top/bottom of your shock mount?

J-Quad

[Bennettj13]

Absolutely amazing work. As an amature fabricator, without access to some of the higher end tools, I can certainly appreciate the amount of work you are putting into this. Even with using the plasma and cad. The amount of hand fabrication is amazing. I love shaping metal. You are an artist. Great job. It's truly inspiring. I won't ***** about making brackets ever again. Again, great job. Don't give up! It really is a work of art. The art is in the details, and you are truly showing how beautiful it can be as opposed to just welding new metal on. I really can't stress how impressed I am with the amount of time, and effort youve put into this. You can certainly tell it's a labor of love.

[Jeff88]

Originally Posted by Bennettj13

Absolutely amazing work. As an amature fabricator, without access to some of the higher end tools, I can certainly appreciate the amount of work you are putting into this. Even with using the plasma and cad. The amount of hand fabrication is amazing. I love shaping metal. You are an artist. Great job. It's truly inspiring. I won't ***** about making brackets ever again. Again, great job. Don't give up! It really is a work of art. The art is in the details, and you are truly showing how beautiful it can be as opposed to just welding new metal on. I really can't stress how impressed I am with the amount of time, and effort youve put into this. You can certainly tell it's a labor of love.

I agree with this!

There is a pretty good book on the market if anyone is a reader.

Michael Perry's "Truck... a love story"

Kinda reminds me of this book when I check in on the thread.

[hallsofstone]

I'm really looking forward to seeing how you bent those edges! End result looks great.

[Pmoreau]

Suspense killed my ***. I still dont know.

[50wllystrk]

Ok, first I say thanks to all. Know this also, I try not to be too proud, I figure you all have learned this by now. Once again, If I inspire anyone to jump into a project, that's great.

J-Quad you had a couple questions about assembly. The nuts are the standard ones that came with the u-bolts. In the end I will use grade 8 flat washers and on the u-bolts and shock mounting bolts I like to use nylon insert nuts, they lock well and never back off later until you want to remove them, also since the nylon part of the nut fits tightly around the threads it helps seal out moisture later. As for never sieze...I didn't think anyone would ask but yes, for any project I will keep for years, for sure I will use it. I've done so much atv and motocycle work especially where a steel bolt is threaded into aluminum, it becomes a habit. Yes, I have to remove the axle again so once it's out I'll weld a strap on the bottom of the mounts. It'll be more convienient then.

[50wllystrk]

Last night I mentioned showing some of the tools. Bennettj13 mentioned earlier that many of the tools are hand tools, nothing special. It does take a while to aquire a large inventory, even of hand tools. One thing I've learned is once you buy a tool you tap into a new world of projects, then the next tool, another world of projects.
First pic is the tool that used for opening the one hole that was off a bit. I've used files and grinding stones but these kick butt. Rotary burr is one name for them and there are many different sizes and shapes.

Once I drilled the first clover to the exact fit I was looking for I declared it my pattern to reference the rest of the drilling of the other plates. In the past u've seen me use vise grips, bench vise and clamps to hold the control pattern to the piece to match it. With this project I needed a more immovable way to keep them together. I tack welded four corners together. Take note...if at all possible if you're gonna do this try to tack weld on rounded edges as I did here or, weld on outer corners. When you are done with the drilling and you cut the tack welds there will be tack weld residue to grind off. With the welds on rounds and corners it's easier to remove the residue vs grinding on a flat area.

[50wllystrk]

Once the plates are tack welded together I used a 1/2 inch bit which is the size of the outer holes. The clover aligned the bit and I got a centering point for every hole. Same goes for the 5/8 hole in the center. I'm one for predrilling a pilot hole with a smaller bit so the centering points give the perfect starting points. Once the pilot holes are drilled then the larger holes are drilled. Everything a perfect match.

Once the two plates are drilled give a quick check on the springs and u-bolts. Looks good, now for the other clover and the other top plate. ALWAYS using the original clover as my pattern to drill from.

[Bennettj13]

If you like that burr in a drill, try it in an air grinder/rotary tool. Just be prepared to really shave some metal.

[Harold_Ray]

How many hours and how many dollars do you have invested so far in your rebuild? Its impressive. I'd like some close-ups of your welds if you have any, they appear beautiful from a distance. What machine are you using for welding?

Thanks!!

Ray

[97zjdriver]

you have inspired me to look into a 48 willys on craigslist near me. there should be more of the trucks on the road instead of in fields. looking forward to more progress on your truck and hope to see it on the road again being used as a truck is supposed to be used for

[50wllystrk]

Originally Posted by 97zjdriver

you have inspired me to look into a 48 willys on craigslist near me. there should be more of the trucks on the road instead of in fields. looking forward to more progress on your truck and hope to see it on the road again being used as a truck is supposed to be used for

In the fields, that is where I see most of them also. Over the years I've had offers from people to buy my truck, even with as rough as it is. I always decline but I fear the right person with the right money may be tempting. My issue is... what would I replace it with? The same thing again!!