Projects 1957 Hillman Husky 392 hemi build thread

Thanks. Car was losing a little coolant too and it wasn't even at 160. It occurred to me today I have one of those Scott Drake radiator caps on the car. Had one before on another car and the same thing happened. Put a Stant 13 pound cap on that one and the problem went away. Going to go get another one today for the Husky. I can't believe I fell for the same thing twice.

 

Here's the steering column apart for new bearings and a lube. Shaft is only 16.5" long. We shortened the original Husky column and machined the bottom to 3/4' DD. The bottom bearing was an aftermarket piece from Classic Performance Products.



This is the trick thrust washer bearing set-up from CPP.



It's called The Steering Column Saver



The top race and bearing balls were a little rusty so I wire wheeled the race surfaces and got a new set of 7/32" balls (insert jokes here).

 

I thought the guy putting a hemi in a hillman would have brass balls

 

Stopped by Control Cables in Sante Fe Springs to have an end swagged on to the hand brake cable. It was pretty cool that they did it while I waited. Hope to have a functioning handbrake soon.

 

Found this pedal in the Control Cables showroom. It's 3/4"shorter than the pedal in the car now so just might be what I need to gain a little more clearance. The pedal I have now just barely clears the firewall and leaves very little room for carpet.




I'll need to modify the lever on the pedal. Coming straight out it hits the frame rail so it needs to take a jog to the right to clear the frame.



Old pedal is 6 3/4" x 2". New pedal is 6" x 2" at the bottom but narrows to 1 5/8" at the top. Every little bit helps.

 

I stopped in there and bought some stuff from them a while back. Control Cables is a great resource. I didn't see that throttle pedal assembly, I might have to check into one of those.
How 'bout some video of the little beast running around??

 

They are a great resource. Kyle was a big help. I had seen their pedals online but seeing it in person was a different story. I knew right away that it was smaller than the Lokar pedal but very similar in design.

I'll work on getting a video posted. Raised the ride height in the rear a bit too much and need to dial it down about a half an inch. Also broke a weld in the driver seat so need to get that fixed.

 

Found some inspiration that he can be when he grows up.

A C/altered Hemi powered Hillman

 

I don't see a steering wheel. Must be driving from the back seat.

 

Yea look at where the pipes exit.

 

Did a little metal repair on the driver's door. The bottom was rusted out so I could see daylight coming through.



Luckily I still have the donor Husky and the door was solid on it. It provided a nice patch panel.

Still has little rust on the repair piece but noting serious. Will grind away what you see in the picture and rust mort anything else.


Ran out of time so will finish welding next weekend. Very pleased with the way it is turning out. All the windows are out for cleaning and all the window channels are also out to get new felt lining. Greased all the winders and latches too. Very smooth door closing now.

 

Sure is a lot of little stuff to attend to on these old cars, isn't there? I pulled the lower left grill out of my '48 Austin to put in a better one - that went sideways in a hurry! Now I've got the whole grill out and trying to repair all the old collision damage to the inner panels and brackets that hold the grill, a straight grill won't fit. Thankfully, No rust so far though.

 

I agree. Every little thing is a project. It's never easy.

Hey Bob, I may be taking a trip up to Valley Springs to look at a car. I'll let you know if I do.

 

There's something worth looking at in Valley Springs? Perhaps another Hillman? I'll send you a PM.

 

Neat little wagon.

 

Here's a coolant overflow tank I added this weekend. The radiator was burping just a little coolant several minutes after shut-down. Came out pretty nice using an original Rootes type windshield washer bottle. I modified the top with a couple of barbed fittings. There is now overflow in case it gets full. I'll watch what it does and can add one later. My other Husky with the same set-up has never needed one in 10+ years of driving (knock on wood).

I've added a little coolant to the reservoir and observed it working. It sucks it back in to the radiator when its cold. It never gets more than about 1/3 full when hot.

 

Took the Lokar gas pedal out and put the other one in.

Here's the Lokar pedal. A nice piece...just wasn't quite right in the small space of the Hillman.

This pedal is from Control Cables. This was the initial test fit. It needs to come out to patch the holes where the other pedal went through. Its hard to tell but there is more room on the top and sides of the pedal so when it comes time to add carpet it has more space. I think this pedal will be more comfortable than the Lokar. The other bonus with this pedal.....I was able to mount it far enough inboard that the pedal arm/lever clears the frame.

 

Got a ton of stuff done this weekend. Had all the door windows out. Welded up the channels and put in new felt to get rid of rattles. Also put in new 1/4 window seals. Changed out all the door windows too since the older ones had welding/grinder slag covering them. Glad I have my parts car still.

Pulled the oil pan off to replace the gaskets.....was leaking a little. So far so good no drips underneath. Also final fit the gas pedal and welded up the holes for the other pedal. Once that was done finished the Dynamat on the floor. I think I'll add some under the rear floor area above the fuel tank.

Tuned the carb too so it idles a little better now. I've pushed it a little and it is a beast.


Just about ready for carpet. Took the car out on the freeway and even with the Dynamat it is LOUD. Hopefully adding carpet will help. Am a little worried that I have an exhaust drone.



Gas pedal is so much better in this position. It's set back from the brake pedal too so no more accidentally hitting the gas while pushing the brake pedal. I still need to add the little plate and felt that seals the pedals.



This seal came from Hillman buddy Frank in Australia. He was nice enough to cut one down from another Hillman model that he makes. Frank is just an enthusiast that is helping keep our cars alive. Thanks Frank! There is another guy in Texas that makes these but charges twice as much and his parts never fit.


Couldn't find a good source for channel felt in the US so had to get this out of the UK. The US sourced stuff wasn't thick enough and was expensive so I found this 3mm stuff from Woolies Trim. It was 1" wide so was a perfect fit in the channel. Was amazed how cheap it was and it arrived via airmail in 3 days!!!! No more door rattles. Now if I can just get the rest of the windows to not rattle. I also bought some maroon/burgundy Hardura from Woolies. That will be used to cover the wheel wells inside the car. Hardura is an embossed PVC vinyl with a felt backing, ideal for sound insulation, as well as under bonnet heat insulation.

Had big gaps at the bottom of the 1/4 window before and the old seal was crumbling. Very pleased with the results on these.

 

Hey, it's moving right along! I still can't believe how nice that big ol' Hemi fits in that little wagon.

 

No new pictures but I have made some progress. Mounted seat belts for the kids in the back seat and got the hardware to install the 3 point belts for the front seats drilled and installed. My buddy Dave snaked in the plates for the shoulder attachment points so as soon as the carpet is in it will get the front belts installed.

Going with black carpet. Hope to have it installed asap.

 

So I've been trying to collect all the parts to put on the window cranks and door handles. The little plastic discs (escutcheons) that go behind the cranks and handles were crumbling and turning to powder. I've looked all over to find some that were in better condition and were not egg shaped from the sun/shrinkage. No luck. I couldn't find anything.

I have a brother with a 3D printer so I asked him to print me a couple. Later that night he had them for me. Had to paint them but they look great. Can you believe you can just print parts like this?

found this description on the web:
The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the entire object is created. Each of these layers can be seen as a thinly sliced horizontal cross-section of the eventual object.

The two on the left were 3D printed. The one on the right is original and had turned to powder.


The little slot is where the pin goes in to hold it in place.

 

.....holy crap...!!!! just how big of a part can be made on one of those 'things'?

.

 

I'm not sure how big. My brother uses it to make helicopter (drone) bodies and other fun stuff. Only downside is that he has to do the sketch of the part and program it in to the computer. This was a simple shape so I think it was easy for him.

We talked about getting a scanner so we can scan and digitize the piece we want made then it will print an exact copy or we can send the file out and have it machined with stainless steel or whatever we want.

I wanted to find an original escutcheon but this thing turned out nearly perfect so I am very happy with the results. Modern technology.....sometimes it's a big help.

 

We now have carpet in and some of the interior panels. All carpet work was done by Rays Upholstery in Watsonville.


I opted for standard black loop with black binding. Simple enough.



It turned out really nice and has a good crisp look to it.



The kick panel under the rear seat was done with Hardura as was original.



Kick panels were done with the same vinyl as on the seats.



Side panels are made from ABS plastic. Originals were fiberboard. Wheel well covers were also made with Hardura as per original.




More of the side panels. Painted these with SEM upholstery paint in a color close to original color.


This isn't original but they also made me a trunk floor mat. Will cut down on the rattles when I'm hauling a load.


Here's a shot of the rear seat with the belts installed. I still need to make the side panels on the drivers side.

 

The expansion tank now has an overflow.....just in case. Tested it in the sink and it seems to work like it should.

 

Lookin' good...

 

Yes it is!

ABS is the best thing since the invention of indoor plumbing!

 

I agree. I used the side with grain so the pattern is similar to the original.

 

I really like how all your interior turned out in the Hilman.
Yep, ABS is light, extremely durable, easy to cut, and it's (reasonably) inexpensive.
Used it for basic black panels in my roadster, cut and drill it, screw it down, done.
Keep those updates coming Husky.

 

There are a couple of ways that parts can be turned directly into solid models for machine production or stereolithography ( 3D printing ), but, that I'm aware of , they involve lasers or co-ordinate measuring machines which the average person doesn't access to.