This page details the ongoing restoration of the "Idaho Special".  

Here is the "Idaho Special" before disassembly and the start of the restoration.  

"Idaho Special" being loaded into Dick's trailor.  

All loaded up and ready for transport to Dick's shop.  Steve and Dick.

The body has been taken off the chassis.  Here a specially made fixture allows the body to be mounted on a rotisserie.  

Underside view of body on rotisserie.

Chassis side view showing new "outrigger".  Specially made by the master fabricator on the project, Dick Shelton.  

New outrigger being designed and installed, only tacked into place in this photo.  Contour of the bottom was designed to exactly match the bottom curvature of the body.

Top view of new outrigger being designed and installed.  

There were two very large holes burned thru the frame, this is the larger of the two.  Here the edges have alreadt been cleaned up. Patch plate is ready to install. 

Custom fabricated patch plate is held in place temporarily with magnets.

The patch plate has been tacked welded into place.  

The patch plate was welded in around the entire perimeter.  Then both sides were ground smooth.  

This is the smaller of the two holes.  Here a patch panel has been fabricated and welded into place.  Area needs to be ground down on boths sides to be finished.  

Seats have been mounted onto new floorboards.  New floor shifter has been installed with custom linkage.

Dick Shelton completing work on the shifter and linkage.  

Dick has fabricated a support structure around the perimeter of the hood opening for added strength and rigidy. 

Radiator mount has been incorporated into the hood surround support structure.  New custom headers are visible.

Twin headers special made by Dick.  

The headers are only tacked together here.  Note custom flanges and nice flow of the pipes.  

The fuel tank for the Wildfire midway during restoration.  Here the circular flange for the fuel tank sender needed to be replaced, so Dick fabricated a new piece and soldered it into place like the orignal Willys flange.  

The fuel tank for the Wildfire required the filler neck to be center-rear.  Willys tank was modified at Woodill Motors.  Note precision of the soldered joints on the end cover-plate and the new filler neck.  Functionality over beauty.  

The Willys T96 3-speed transmission with overdrive was completely rebuilt.  

The T96's Overdrive used a solenoid, relay, reverse lockout switch, and governor mounted externally on the transmission. A kickdown switch and second relay were also needed, mounted remotely.  Wiring for the unit has been started.  

The Flywheel has been surfaced and a new pilot busing has been installed.  Note how new bushing has bled outwardly, due to bushing being oil-impregnated. New Clutch pressure plate and disk, along with new throughout bearing.  

Beginning the process of windshield design and fabrication.  This is one the biggest challenges that Dick and Steve face.  

The top edge of the body where the windshield will mount has been fitted to this mold.

The mold is built using multiple layers of dense foam board.  Then it is contoured, sanded, then sealed.  

An impression is made off the mold.  The light colored areas are the backside of the impression.   

An impression is made off the mold.  The black colored impression is what will be used to form the windshield.  

Dick shows the impression as it is taken off the mold.

A small test section is shown here.  The process has been fiqured out.  We will pause the forming of the final windshield until the bodywork is all finalized.  More on this to come!

Hood underside showing Factory hinge and latch system.  Also, a Factory strengthening rib running down each side.   

It was determined that a single cental hinge was not ideal, so a dual hinge system is being designed.  Here the old hinge structure has been removed.  New stengthening ribs and pads are being shaped.   

The ribs and pads have been shaped, they are ready the be "glassed" into place using resin.  New hinge pads tie in with Factory ribs, thus translating the forces the length of the hood.  

Part of Dick's secret method is shown here.  The area is covered with aluminum foil.  The top of the foil is now sprayed with releasing compound.  

Dick's secret method next stage.  The area is covered with fiberglass mat, soaked with epoxy resin, then rolled smooth, removing air bubbles.  It is allowed to cure overnight.  

The newly created fiberglass section is removed from the foil.  The foil is then cleaned off, and the section is test fitted to the hood.  Note wood jig holding hood in correct shape.  

Hood hinge supports are made of steel, with thread inserts, mounted on the underside of the new panel.  

Hood hinges are partially fabricated, shown mounted to new section.  The new section is ready to be bonded to the hood using epoxy.    

Door fit is being addressed.  Some spots are high, some low, gaps vary.  Top edge where the Corvette chrome moldings once were glassed on, can be seen, this will be ground away.  

Gaps are being noted.   

Curvature fit is being assesed.  

To achieve the desired fit, the door needed to be cut apart, to allow the thicknes to be adjusted.  Shown here cut apart, then temporarily held into new position using metal straps.  

New door latch can be seen as it is located for attachement.  Door jambs now will be glassed and then sanded.  

After the jambs have been fiberglassed, and sanded, the latch location is marked.   

Door jamb has been cut away allowing the new latch system to mount.

New latch, and custom fabricated mounting plate.  

Doors are strong structures, shown with new latch.  

Maintaining correct height and conntour is important.  

Guide rods helping to define and maintain the contours.  The Passengers side door is being worked on here.

Clamps holding new underside support.  Drivers Side.

Filling the void with fiberglass mat and resin.  Drivers side.

A fixture made of cardboard was constructed to enable fitment of the grille.

Fixture and grille both shown here, after grille has been installed.  

Showing the relationship and fit of the fixture over the grille.  

The cardboard fixture was then placed on top of a grille that is in better condition than the "test fit grille".   

Full sized Willys Aero grille is marked so it can be cut.  

The attachment of the grille is being fabricated.  Ends will have hidden supports, that will be custom molded. The process is being started here.  

Newly fabricated steel brackets can be seen here, attached to the grille.  

Bracket has contoured edges for increased strength.  

A mold is being formed on each end, so an impression can be made.  

Clay is used to seal the edges prior to filling  the molds.  

Grille shown mounted, further detail photos of the end mounts, to come.

The modified Grille, back from the chrome plater.     

Terry, owner of Custom Plating Specialist, took care of our chrome plating needs.  Willys Grille had two dents, was badly rusted, pitted, had two holes welded-closed, had both ends shortened, and had its center support rib reduced.  

Underside of Grille after copper and chrome plating.

Customized Willys Grille for the Idaho Special shown above custom fabricated Grille for the Brushfire.  

Cracks below the grille opening, and bumper bracket holes need to be repaired and filled.  Areas have been prepped.  

Several layers of fiberglass mat are used. 

Clamps and a wooden jig are used to hold the fiberglass panels in the desired position.  The rear section had been modifed at the Woodill Factory when the car was converted to a Corvette windshield and hidden folding top.  The hidden top was located under this panel.  

A chain and a strap are used to pull the body together.   

A view showing gaps that need to be filled. 

Positioning the trunk. 

The trunk was twisted out of shape, so a wooden holding jig is built to correct the situation.  

Wooden holding jig completed. 

Holding jig, front view.  

Holding jig, rear view.   

The headlights on the Idaho Secial were glassed into place at the Factory, with no adjustment provision.  Adjustments were desired, so a custom molded mounting system is being fabricated to solve this problem.  Here an imprint of the headlight bucket is being taken.   

Imprint taken apart. 

One half has been built.  

Inside view of the Impressions. 

Molding the final part. 

Removing the part from the mold. 

Threaded inserts can be seen in final part.  

Headlight buckets have been attached. 

Newly fabricated steel mounting ring can be seen attached to the headlight bucket.   

New headlight mounting system has been completed.  Now the headlights can be adjusted.