The Joburg Traveler

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
I think my evaluation of the Willys Traveller is complete. I've had some time off so I spent that time going through the history of Willys and all the characters involved. I have to say that is a great story within itself and I literally spent three days just investigating what these guys were up to lol, what challenges they faced and how they sought to overcome the business and technical challenges of that time. It's fascinating stuff
The other 4 days or so I spent under, in and on the Traveler, whilst downloading as much technical information that I could ( thank you so much to all those who have contributed to what is a fantastic library and information source on this forum) and familiarizing myself with the suppliers both local and abroad, what they offer etc.

I've apparently taken to speaking to myself quite loudly and on occasion the wife has come through to the garage as she thought perhaps we had visitors, but no as I explained to her I have a special friend now and we talk...

The dreaded requirements list has started and the the first thing I will be doing is sorting the leaky Carter, I think I have found a replacement. The manifold gasket is gone so I have one of those and will be installing it once I have the new carb. Then we'll set timing and see how Willys fires up. The brakes need work, master cylinder has a leak and I will get that replaced alongside the drums and new shoes all of which I have found locally.

I've decided that my special friend needs to get back to original shape ( We discussed this and it was agreed) and as such we will first install and setup everything engineering wise to spec, with the exception of tires, I want those thin radial Yokohama's lol. However I am of the opinion that an electronic ignition, Weber carb and discs in the front might become engineering vers 1.1. But all in good time lets give the setup a chance.

I've managed to locate a fabricator who feels he can build the vintage roof rack I saw on the Mopar Willys which I love so that's a bonus, he also has a connection who is able to recreate an original sun visor and step plate which I think adds to the vehicle, plus its African sun...

I'm chatting with an ac specialist company and they are keen to see if they can sort some chilled airflow for me without sucking all the horse power. I'm not at all educated in that department and have a lot to learn.

I found some rust underneath the right hand panel connecting to the fender so when we do the body work that needs to be cut and sorted. The 44 and 25 Spicer differentials look okay, I've drained all the oils, flushed and replenished with new. I might have a back side shaft that needs replacing, however a friend of mine is a specialist in that department so he will look see what needs fixing.


The entire inside base of the vehicle was lined with what we call "Bakkie paint" which is a rubberized product that you paint into the bed of your pickup for protection, (or just before you sell your Pickup to hide rust :)) I'm not mad about it so will decide when we get Willys to the body shop whether I want to keep it or not. There has to be more elegant options lol plus I want to reinstall the wooden rail liners in the vehicle.

So I'll update as I go along but for now that's the state of the Traveler in Joburg, this is huge fun.
 

Pivnic

Well Oiled
Nov 24, 2009
3,909
Conifer, Colorado
First Name
John
Willys Model
  1. Pickup
Willys Year:
  1. 1957
Hi Garth. It's good to hear that you are taking the time to 'learn' all about your Willys Vehicle and are beginning to formulate a PLAN! I think you will have a successful project if you continue these good habits throughout your project. Post pictures along the way and keep us all informed of your progress. Good Luck, Pivnic
 

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
I've been waiting for some parts for the engine so thought I'd use the time to get to grips with the transmission and see what's in store for me. I went through Petes's thread and postpositions about his transmission and transfer case rebuild which has been really helpful. At one stage I thought that perhaps our PO's were related
image.jpg
As can be seen my PO had a great love for what we call "Bakkie paint" and as in Pete's case I could not locate the inspection thingy majig but a little perserverance and what do you know

image.jpg

Cleaned it up and found some strange unsecured bolts without nuts

image.jpg

That could have ended in a little frustration I guess if I was on the road. Makes me feel great about getting stuck in as a green horn and doing things myself, (with a lot of guidance and help from you guys).

So got the transmission inspection cover off and it looks like this, I say "this" as if I'd just stumbled upon the arc of the covenant as it's the first time I've ever done this and there was of course a lot of praying and promises of sacrifice.

image.jpg

Of cours whilst everything was foreign to me I did recognize the rust!
So my question is how do I deal with that?

To to be continued
 

Pete

Founder/Owner
Staff member
Administrator
Sep 17, 2009
7,243
Hailey, Idaho
First Name
Pete
Willys Model
  1. Wagon
Willys Year:
  1. 1960
Garth- that bedliner stuff that was put in your Traveler looks way more nasty than the stuff in mine, I feel your pain... I would love to get rid of mine, it is like 50 grit sand paper.

Looking forward to your updates.

Pete
 

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
Hey Pete

its strange stuff, doesn't really adhere to the metal but creates this plastic layer that sits on and above the surface, it's all got to come off and who knows what surprises are waiting for me underneath. I'm hoping the dry storage time meant that any water that had found its way under this plastic dried and that the primer and paint that had been applied did its job, time will tell. A body liner/chassis liner is sprayed all over the chassis and undercarriage of the Willys and that has worked well, really good adhesion and definitely offered protection to all those parts. I've decided that we will do a complete overhaul of the transmission and transfer case. Make sure it's sealed properly and then have that peace of mind that it's done to spec and no need to go there again for hopefully a very long time.

cheers

Garth
 

Hiki

Bigger Hammer
Sep 19, 2009
63
East London, South Africa
First Name
Hiki
Willys Model
  1. Wagon
Willys Year:
  1. 1947
Hi Garth - so good to hear that there is someone here locally with another Traveller. I purchased one years' ago from a guy in Bloemfontein, using the chassis and drivetrain only. Still have some body parts stored away, scrapped the bulk of it, too rusted. Recently I sent the back stepping plate off to a friend in the USA that needed one; no idea then that someone here is looking for this plate! Should you be able to manufacture the rooftop spare wheel carrier, please advise as I would love to procure one.... Groete
 

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
Hey Hiki

Good to meet you. I'm starting to meet more and more South Africans who are Willys owners, not so many who own the station wagon body style like ours, but it's encouraging. Hiki do you have a set of front seats or frames? Also if you have extra side benches of the Traveller I would be interested in those. I'll definitely keep you in mind for the spare wheel carrier and will keep you up to date on the rest of the parts I have fabricated here. One more question. On the bottom of that step plate did it have a housing at each end for a bolt which is screwed through the rear bumper support arms ?
Have a great weekend

regards

Garth
 

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
Hi Dan

thanks for the picture. Dan did the original Traveler have a single front bench seat as in the Truck or did they have the 2 +1 arrangement of the Sedan Utility?
 

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
Doge thanks for the reply. So that connected up to the prop shaft e-brake and engaged the two back drums as well?
 
Last edited:

oruna1

Sharpest Tool
Apr 28, 2011
368
Long Island, New York
First Name
Ron
Willys Model
  1. Pickup
Willys Year:
  1. 1962
There is no prop shaft e brake, Look up and download the service manual in the library section of the forum and you'll have good info for the e brake set up.
 

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
Okay solved it, found this on line.

TRANSFER CASE MOUNTED HAND BRAKE SYSTEM (Which I have)
The first type as used on the MB/GPW/CJ-2A/CJ-3A/CJ-3B/CJ-5/CJ-6/FC-150/FC-170/M38 and M38A1 consists of a hand operated lever that operates a cable through a conduit that mechanically expands or contracts a unit mounted on the back of the transfer case. The M38A1 incorporates a hand operated lever that operates a rod through the floor which actuates a unit mounted on the back of the transfer case.




REAR BRAKE DRUM MOUNTED HAND BRAKE SYSTEM
The second type as used on the Jeepster, Utility Wagons, Utility Trucks, the DJ-3A and some FC-150 and FC-170 vehicles consists of a hand operated lever that operates a cable through a conduit that actuates a crossmember mounted lever that in turn actuates another cable or pair of cables that actuates the rear brake shoes with a system of struts and levers.
 

scramboleer

Super Moderator
Staff member
All-Star
Aug 16, 2011
8,745
San Francisco, California
First Name
Dan
Willys Model
  1. Wagon
Willys Year:
  1. 1964
Hi Dan

thanks for the picture. Dan did the original Traveler have a single front bench seat as in the Truck or did they have the 2 +1 arrangement of the Sedan Utility?

Hi Garth,

I believe that they were split seats, like Paul Barry's Traveller at Willys America:

 

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
So the last part of my fluid service was to check on the coolant situation and set up of Willys. Unfortunately due to an irregular part being used instead of a standard Stepcock in the bottom of the radiator I couldn't do what one would normally do to flush the system. The normal 30 minute coolant maintenance cycle turned into a long morning.

I tried with extreme care to remove this stepcock impersonator

image.jpg

and had to loosen the shroud and remove a proprod to do so.

image.jpg
Unfortunately the end result was that I had to brake it off, it was rusted and fused beyond repair. I made the decision knowing that their would be additional cost in repair, but I want things proper. So...
image.jpg

image.jpg
As I removed the bottom hose connection I watched the coolant running out into a container I have and it was surprisingly clear, a little rust tinge but really nothing.


I flushed it and then filled it with flushing liquid let it sit for a couple of hours and flushed again. Doesn't seem to be any problems, but a pressure test will confirm that at the radiator repairers.


The stepcock on the block was in good shape and the little coolant left dribbled out miserably.


I checked to see what thermostat was installed and it seems there isn't one. Years ago it was common practice with older engines (in South Africa) to remove the thermostat. However this engine had been rebuilt and I would of thought that a thermostat should be included in the rebuild when the PO did the overhaul.


But this has been the theme so far, Willys is good looking on the outside but inside...trouble. I dated girls like that years ago, married one and that hasn't turned too bad at all, so I'm hoping...
 

Garth

Well Oiled
Dec 26, 2014
1,289
Johannesburg, South Africa
First Name
Garth
Willys Model
  1. Wagon
Willys Year:
  1. 1960
Removing, inspecting and cleaning the Carter carb

The weekend was spent getting my head around the Carter carb, so I was reading up and watching various videos in the YF model which was useful. The carb had been leaking badly and with fuel spilling out into the manifold it needed to get urgent attention, as I am also replacing the manifold gasket it made sense to get to grips with my first carburetor overhaul.
image.jpg
So I removed the carb and disassembled it

image.jpg

It it was filthy and to tell you're truth it emitted a real bad smell.

On inspection it was decided to fit a major overhaul kit which basically comes with everything new including gaskets etc. I then soaked the carb body for 24 hours and cleaned it with a soft tooth brush and it came out new, but hang it was filthy. And that smell...

next up we'll be replacing the broken manifold and exhaust gasket

image.jpg

Picture re shows the blown gasket still attached. Will clean that up. Anything I should be checking for whilst I'm doing that?

just heard that the North East USA is about to be hit by some nasty weather. I was in New York last year in January and it was cold. Nothing like this though. So those of you residing in those areas take care
 
Top