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A little project update on Chug A Lug

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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Topic: A little project update on Chug A Lug
    Posted: 9 hours 16 minutes ago at 11:01pm
I have most of the individual circuits drawn out. And that will go in my manual.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mike F Quote  Post ReplyReply Direct Link To This Post Posted: 20 hours 56 minutes ago at 11:21am
Mark you may want to put together a schematic on the wiring also. As the stock one will have little relevance here. Not just for future generations, but also for yourself. CRS will eventually set in (if it hasn’t already) and it may prove invaluable. Wink
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 23 hours 13 minutes ago at 9:04am
The switches will all be engraved with their function. The bottom 4 are all simple push pull on off to control what will be on their knobs. The dual light switches the one on the left will be as a conventional light switch the one on the right might need some explaining. As will the fan switch.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Ol' Unreliable View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ol' Unreliable Quote  Post ReplyReply Direct Link To This Post Posted: 18 Aug. 2019 at 11:28pm
You need to put together a manual of how to use all those switches for after you're gone (many years from now, that is) and someone else ends up with the Jeep. 
There's a reason it's called Ol' Unreliable
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 18 Aug. 2019 at 11:08pm
Borrow away. I have a whole wall of photos down loaded off the net that have inspired or helped me plan my build. I owe much to many many other Willys owners.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote CJ2A-CT Quote  Post ReplyReply Direct Link To This Post Posted: 18 Aug. 2019 at 8:35pm
For you, this is a simplified dash, for the rest of us it looks like an F35 cockpit..........I enjoy this thread and continue to borrow ideas, thanks
46 CJ2a 22786------Rebuilding "Briar Rabbit" with Son-in-law, Jason
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 18 Aug. 2019 at 8:02pm
A few less my T800 has a pretty complete dash with 4) 2" gauges left of the Main display with Tach and Speedo and a digital display above outside temp, hours and odometers below. Then 12 gauges to the right, and maybe a dozen and a half switches from 3 to control lockers to TAG axle make cruise DEF work lights even a switch to control what the digital display does. I can even get the thing to communicate to me in 4-5 other languages. Then add in the Wet kit 2 hydraulic levers controls for the tailgates and auto tarps even a control to stretch the Reach. 18spd Tranny

And it rides like a 3 legged mule someone bolted an Oak church pew on top of and sent across a plowed field at a gallop. 10+ hours a day and I'm worn out.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuzonRed47 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Aug. 2019 at 6:28pm
Mark, your jeep must have nearly as many controls on its dash as the big trucks you drive at work...wow!
CJ2A #140275 "Ziggie"
ACM #124334
1953 Strick M100 trailer
Serial #18253
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 18 Aug. 2019 at 6:24pm
DASH
So I think I have everything fit into the dash. A couple of the switches will still need to be pulled to attach wires. What a PITA. amazing how many more wires you can end up with when you add a few things LOL. The switches on the left are starting on the top left

Wiper/Washer (2spd intermittent with a push to wash)
Engine Fan control (Auto-On-Off)
Main Light Switch (Head, Park, Tail, Side marker, Dash, Dome)
Aux. Light Switch (Fog, Driving, Under dash Rear Floor)
Backup (manual control separate from the switch on the Shift tower)
Line Locks
On Board Air Compressor
Inverter
Spare

I can tell that once I get the Tub on the Chassis wiring is going to be a huge hurtle this winter.


Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 11 Aug. 2019 at 7:43pm
OK so after a fun 63 hour work week. I got out in the shop about 7:30 this morning.

I made amber under dash list that will also serve to hide my fuel pump shut off switch (anti Theft) I cut a clearance light in half and then just used the amber lens pieces. Mounted up under the dash out of sight.

Next up was the Fan control switch (I have a 3 position push pull switch to control my electric fan AUTO - ON - OFF) this involved some pretty wild contortions as I had to grind off part of the reinforcing layer around the steering column mount so the switch would mount flat. I have the tub on its Right side and while looking through the steering column hole and reaching through the Master Cyl fill cover holding my Dremel tool I managed to git it done. WHAT A PITA.

And third was the Wiper/washer switch. Its a great big thing having intermittent and 2 spds plus the push to Wash control. Not as big of pain as the fan control switch. But it came with a little bonus problem. I am going to run the wires to the motor (which is mounted to the top right inside of the windshield frame like where a sun visor on the pass side would be) to do this I had to drill a hole just above the Column shift notch in the dash. Well I had already put my fancy duct work on the dash so all that had to be removed to drill the hole in the process I cracked one of the joints so that had to be addressed.  Its done now and I will maybe to a little touch up painting later.

I figured out how to wire my 67 Chevelle Headlight switches and thats the next challenge to get the two of them pigtailed. I am using two headlight switches to control various lights.

Main switch
Head Lights bright and dim
Park lights
Tail and side marker lights
Dash
Dome

Aux. Switch
Fog
Driving
Under Dash and rear floor


interestingly enough I will have a dedicated manual control switch for the Backup lights

So three light switches all total.

Things to figure out where to locate now include a Windshield Washer reservoir and pump. And the Electric fan relay and fuse (I think this will end up on the side of my battery hold down setup. Along with the Headlight, Fog and Driving light relays.

MAN do I have a lot of wire!


Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 10 Aug. 2019 at 8:54am
I have not slept in CHUG but I have laid down in it a few times with dates in High School and Just after. If you remove the Pass seat and drop the tailgate throw down 2-3 thick sleeping bags well you get the idea LOL. That was about 100 lbs and 4 decades ago though.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Greaser007 Quote  Post ReplyReply Direct Link To This Post Posted: 10 Aug. 2019 at 2:00am
Mark,

   That Willys is so clean, if it were mine, and there was enough room, i'd sleep in it.    hahaha

   You know, I am going to have to set aside a full day to read through 86 pages in this build-thread.

   I'm wondering if we ever do 'finish' one of these. :)

   Len
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 15 July 2019 at 9:22pm
The Keyed coil spot is a piece of 1.125" Redish/amber Phenolic rod I turned on my lathe to fill the hole. I thought it looked nice so I polished it up and made a collar and center bolt to lock it in place.

So its officially a pretty hole plugging thingy that serves no real purpose. The three black button heads around it serve the same purpose but aren't quite as pretty LOL.

I don't know why I didn't fill in the coil/ignition hole I had no trouble filling in the Governor control hole or even the original headlight switch hole to suit my purposes but I went this way instead. 
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote chasendeer Quote  Post ReplyReply Direct Link To This Post Posted: 15 July 2019 at 10:11am
Whats in the keyed coil spot?
Jay
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 15 July 2019 at 9:25am
The left side will look a little bit less Factory as it will end up having 9 switches 8) Push/Pulls and one Rotary (windshield wiper and washer) they will of course have the matching knobs. But yes I am trying to keep "The Look"

Thanks for noticing.
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuzonRed47 Quote  Post ReplyReply Direct Link To This Post Posted: 15 July 2019 at 8:33am
Mark, your jeep's instrument panel looks 'factory'! Really nice work.
CJ2A #140275 "Ziggie"
ACM #124334
1953 Strick M100 trailer
Serial #18253
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 14 July 2019 at 9:18pm
Oh I should explain a couple things.

The two lighted armored Green Switches in the middle of the Dash will control the E-Lockers once one of these switches are switched on then the Push Pull Switch on the Shifter will actually control the Locker.

The odd looking dash light is actually a repop Cigg Lighter with a built in Dash Light it also lights up on the end if the lighter is pushed in. Something I found on eBay I just had to have.

The push pull controls at the top of the Dash are from the left the Fresh Air intake damper, then the Warm Air intake control and then on the right side of the Dash Light/Cigg lighter the Choke.

I would have preferred the choke on the far left so its in the same area as the Ignition switch and Starter button. BUT the Fresh Air intake is a full 5" long pull to close so keeping it close to the column seamed like a good way to keep it out of harms way and it also allows the cable which will need to be .050 Piano wire to run very straight. The Choke is a Bicycle Brake cable so it bending a little is no problem.

Extra Gauges are on the left the Transmission Oil Temp Gauge (the sending unit is in the Tranny fill bung hole. I had to have some sort of gauge on the Tranny Transfer OD and since they all share oil and all can be filled via the Transfer case Bung hole (which has a 6 lb magnet in it) I figured this would be a way to monitor the Gears Boxes on long trips.

Then on the far right the Air Pressure Gauge for my ON BOARD AIR system. The system will run between 110 and 145 PSI so the 150 PSI gauge seamed perfect.

And then the lower 3 knobs are the Heater. 3spd fan switch/Defroster diverter/and Water temp control (I am using a 67ish Bronco type valve)

I might paint this panel Satin Black at some point.

You will notice all the knobs look very much like original Willys knobs I searched a long time to find them (then they were only $.69 each LOL) once I have other more important things done I am going to have each of them engraved with their function and will put White lacquer in the engraving.







Edited by Mark W. - 14 July 2019 at 9:21pm
Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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Mark W. View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark W. Quote  Post ReplyReply Direct Link To This Post Posted: 14 July 2019 at 9:06pm
Herculiner a little 1 quart can from NAPA. I used a chip brush with shortened bristles to kind of dab it on so I could control the texture and get it kind of even. I'm happy with the way it came out. I need to dab a little Satin black paint on it in a couple places over spray found a way past my masking job on the second go around painting the tub.

And thanks I just hope putting the Tub on the chassis isn't to big of a PITA with the extra weight.


Chug A Lug
1948 2A Body Customized
1949 3A W/S
1957 CJ5 Frame Modified
Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962
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