What did you do on your Willys today - Feb 2020

Today, I had a wiring project to tackle.

I did not like how my GM alternator was wired. For the output line, I had 14 gauge wire. I thought this was too small. Also, I did not like looping the voltage sensing wire directly back to the output lug. It is best to have it some distance away to get a better reading.

I found some very flexible 8 gauge wire. I ran this from the alternator to the negative side of the ammeter. Then a line from the positive side to the positive side of the floor starter switch. It took a while to measure, cut and route the heavy wire. I had to use a propane torch to solder the lugs on.

Since I had the original ammeter out, I stripped off the orange paint from the rim and repainted it black. Now, only the oil pressure has the orange rim.

I reused the 14 gauge charging wire as the voltage sensing wire and connected it to the positive side of the ammeter. I connected this and the “key on” signal wire to a new plug with a built in diode.

Next, after 73 years, it was time to retire the original keyed coil. The key was getting pretty sloppy and I was concerned that I had a parasitic draw. (I’m going to hang on to the coil.) I had to make up a couple new wires.

I had planned to add the GPW/MB circuit breaker. Ever wonder why there is a square hole in the center dash support? I planned to put the ignition circuit and fuel gauge on the 10 amp breaker, since this circuit is not protected. The rest of the Jeep is protected by the 25 amp breaker on the back of the light switch, which I replaced last week. I was going to use the 20 amp breaker for the Harrison heater and a cigarette lighter socket for phone charging. Since I haven’t installed the heater and socket, I decided to save this for a future date. This project was taking enough time already and soldering up a bunch of new wires was going to take too much time.

When playing with an old electrical system, I always dread hooking up the battery again. All went well and nothing fried. The new starter switch worked. Everything came to life. I may have killed the fairly new temperature gauge. The wire pulled out of the sender when I was routing wires.

So, that killed about half of the day. Another project completed and maybe one added.

Micah

Today’s project was the handbrake.

In the past few months, this was the third time I have been in there. First the rod and spring popped off the lever. Then, with it all back together and adjusted, I couldn’t get enough tension in the cable to get it to hold. This time, I replaced the rod and lever. I just about had it all back together when it popped off again. This time at the arm socket. I set the lever/backing plate clearance at 3/32 but, if I pushed the lever toward the plate that last little bit, it would pop out again. So, I made sure to keep forward tension on the arm while I reconnected the cable. I’m wondering if there is excessive wear in the arm socket and/or pivot. Hopefully, it stays together.

Why did Willys have to design the handbrake so that you have to pull it all apart to service? If drive shaft bolts holes on the yoke were threaded, the drum could have bolted to the yoke and been made removable. Just frustrating after pulling it apart so many times lately. Plus, I had to disassemble it three previous times before I got a seal that would work. I cringe that I damage the seal each of these last three times I have been in there. I didn’t drive today. So, hopefully it remains leak free.