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Willys M38 Build

Covering the overall build of my Willys M38 copy. The plan is to build a flat fender for general wheeling and holidaying around New Zealand.

New floor, side and step

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September 12, 2011

We folded up the basis of a new floor and new side panels. I cut out and Don showed me how to beat and fold up, then weld the replacement step. He made it look easy!

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Wainui Willys Works Camp Trailer Mark 4

August 20, 2015

As we've punched a few trailers out now all based on the same frame and panel spec, it's been cool to see how they each get customized and evolve along the way. This is the latest (and last) trailer that'll be coming out of the workshop for a while I would say. Don started the camping trailer trend with a modified garden trailer with fibreglass lid that was upgraded with bigger axle, shocks, brakes, cooker, fridge etc. Roll forward to 2015 and three more were built - Daves as a utility unit with an open top and painted canary yellow to pull behind his (also bright yellow) CJ5, Then came Phils and mine in camp spec with lids, fridges, cookers and stereos. We have significantly different track widths between the two as Phil is in a TJ whereas I tow with the mighty M38 Willys. Finally, Don gets to build his own up-spec version. We were lucky to develop on his initial ideas for our trailers and now he has taken the evolution even further with some cool extra ideas and changes...

It's been a while

March 15, 2019

So after the last couple of years playing around in the Jeep I have gotten bored with not working on it so have commited to some upgrades. These will take me a while and will start in my own garage and then likely migrate out to Don's for the things I'd really appreciate his help on. Design plan is a VN Commodore V6 (Buick LN3 fitted to FWD Pontiac/Buick etc in the USA) mated to an SM465 using a Chevy S10 bell housing. Advanced adapters kit to fit the trans to the D18 transfer and I'm still planning on running my overdrive for now - we'll see how it all holds up. I'll need to regear but that'll be once I'm back on the road. We'll also be going to hanging pedals with boosted brakes and fitting a Saginaw steering box up front. So far I have rebuilt the engine with new pistons and rods, gaskets seals etc. The gearbox has all new bearings and I've replaced all gears also so it'll be like new. The transfer will be a fresh build (I have most part...

Exhaust and brakes

June 02, 2012

Been quietly plodding away on the Jeep still though haven't had the camera out there for a while so no posts. I've made up some roll cage mounts off of the chassis behind where the seats will mount and rebuilt the water pump with an omix kit. I've also fitted Toyota MR2 rear brake calipers and Suzuki Vitara rotors to the rear of the Jeep to make it 4 wheel disc braked and also the MR2 calipers provide a decent mechanical handbrake. Overall a pretty straight forward conversion with help from Don in designing the caliper brackets that bolt on to the stub axle flange. I've also had a crack at making the headers which has been a learning experience. I had to modify the front plate of the motor to fit my fuel pump in first so I had everything in that was going to be in the way. You can see in the picture below, the lower diaphragm (vacuum wipers) slots into the plate. Don had me draw up the flanges and get them laser cut at the same ti...