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1940 Willys Cabover Custom COE Chassis Swap and Build

1940 Willys Cabover Custom

This is a very well photo-documented build that combines a 1940 Willys Sedan and a 1992 Dodge 1 ton extended cab pickup truck, and a whole lot of metalwork.

There are 13 slideshows from start to finish and a final drive video. The video descriptions below are as written by the builder/video maker: Chris Boggess, Hot Rod Technology Instructor at Utah Valley University.

1940 Willys Cabover Custom Slideshow 1

Published on Nov 16, 2012
“Getting started. Taking a 1992 Dodge 1 ton extended cab pickup. Lengthening and widening front fenders. Building a new 3 inch wider nose piece. Cutting body in half front to rear and widening it 4 inches. Lifting it on to dodge truck frame and getting it set where it will stay.”

1940 Willys Cabover Custom Slideshow 2

Published on Nov 24, 2012
“Getting body set where it will sit on the frame. Building body mounts. Mounting front fender and changing door to accept where the fender will sit. Moving firewall back. Adding to rear doors to make them square. Building of hood sides. Finishing the front nose piece inside by the engine compartment.”

1940 Willys Cabover Custom Slideshow 3

Published on Dec 4, 2012
“Taking a 1937 Willys four-door Sedan and putting it on a 1992 Dodge 1 Ton chassis, with lots and lots of custom panel work ( like the hood, bed and rear fenders). Much more too. I used a Brinks armored car to get the Alison transmission, Cummins diesel engine, radiator, and driveline to power this Willys. In this show I build the top of the hood and get the hood hinges on, cut louvers in the front of the hood. Get the hood lock put in. Get to see the brinks armor car. Installation of the exhaust system.”

1940 Willys Cabover Custom Slideshow 4

Published on Dec 14, 2012
“Cutting off the 4 door trunk section and making the new truck back panels. Building inner wheel wells for the bed. Choosing what kind of bed to build. Building the bed rails. Building wood bucks and paper patterns. Building the right rear bed side.”

1940 Willys Cabover Custom Slideshow 5 ~ Panel Fabrication

Published on Jan 18, 2013
“Building of bedsides. Making rear fenders.”

1940 Willys Cabover Custom Slideshow 6 / Metal Shaping

Published on Jan 18, 2013
“Working on the rear panel of the truck bed. Tearing the truck down to send to the sandblaster. Working on the inside of the rear doors. Making inner wheel wells to go up under front fenders. Finishing the grill openings. Welding the rear portion of the cab onto the body. Making gear shift and emergency brake box.”

1940 Willys Cabover Custom Slideshow 7 / Metal Shaping

Published on Jan 27, 2013
“Finishing up the floor in the rear of the cab. Widening rear window fame and front window frame. Putting inner wheel wells and bedsides together. Finishing wheel well opening on the right rear fender. Making splash aprons and running boards to go under the cab sides.”

1940 Willys Cabover Custom Slideshow 8 / Panel Fabrication

Published on Feb 3, 2013
“Finishing up rear panel on the truck bed. Finishing up rear splash apron under bed and running boards. Finishing up left rear fender opening and the bottom of the fender. Heading off to my first car show with this car to show the public what I have been doing.”

1940 Willys Cabover Custom Slideshow 9 / Sheet Metal Fabrication

Published on Feb 10, 2013
“Building of inner bed panels. Working on the dash. Putting in the air conditioning controls. Fixing trailer hitch receiver cover. Frenching in the license plate in bed, putting in third brake light, fixing door latches, and dovetail.”

1940 Willys Cabover Custom Slideshow 10

Published on Feb 18, 2013
“In this slideshow, we fix the door latches, the dovetails, make an air intake for the engine, install stainless steel spring to run electrical wires from door to doorposts, fixing the heating and air conditioning ducts with fresh air coming in and cold air going into the cab. Also mounting the rear window air conditioner, building steering drop and a cover to cover the steering column, working on the overhead console, mounting windshield wiper motor, putting in defroster vents, and seat belts.”

1940 Willys Cabover Custom Slideshow 11

Published on Mar 4, 2013
“Getting the truck ready for paint. Deciding on the instrument layout on the dash. Painting the frame and body. Starting to put the truck back together. Taking out the dents in the stainless steel door handles.”

1940 Willys Cabover Custom Slideshow 12

Published on Mar 15, 2013
“Building exhaust heat shield, putting in the insulation in the roof, installing the overhead console, putting dog house for the last time, color sanding and polishing paint, building a new floor for the bed and installing and painting it, making patterns for windows, installing windows, putting in fender beading, making thresholds, making exhaust tip, inner wheels, pushing truck outside of the shop and looking it over.”

1940 Willys Cabover Custom Slideshow 13

Published on Apr 6, 2013
“Putting on the Willys emblem on the hood, making rearview mirrors out of stainless, making Willys emblems for rear mud flaps, mounting rearview mirrors, building bumpers and brackets, seeing the finished product at the Deans day at UVU.”

1940 Willys Cabover Custom Slideshow 14 / Drive-By

Published on Nov 5, 2013
“After many requests for a drive of the Cabover and me saying it over and over again, I finally did it. Enjoy…”