World War II Jeep Repair

Ford  GPW World War II jeep
The engine cylinder head off from WWII jeep
Crack In Cylinder Block from WWII jeep
Original Bolt and modified Stud from WWII Jeep
Setting the epoxy resin from WW2 Jeep

I bumped into Kevin and his WWII jeep at a local show. He was expecting to do some work on the engine of this jeep to keep it running.

These WWII jeeps were made for use in war and originally expected to have a short life of about 60 days. This one is still going strong after 60 years! You will recognise this type of vehicle from war films such as 'Saving Private Ryan' . I am told these films often use post war manufactured 'jeeps' which really annoys the purists, the directors are suspected of doing this deliberately! This is the real thing.

Cracked Head

A while later Kevin called me asking if I could help with some repairs. He had taken the jeep head off and found a crack in the block (see picture). Also a stud repaired and replaced years earlier had broken and an original bolt had stripped its thread in the block. Kevin didn't want to go down 'iron stitching' or welding with this crack as this would likely need a complete strip down to remove the block. I suggested using a high temperature epoxy resin to run into this crack and stop a potential path way to the cylinder bore. You can see that the block has had liners fitted in the past reducing the chance of the crack reaching the cylinder bore.


The stud repair was agreed to make new studs with oversize threaded ends for the existing 'repaired' stud and tapping out oversize for the stripped thread. I made these studs from  1/2 inch UNC high strength cap screws. They were machined to the 7/16 head bolt diameter for most of thier length with 7/16 UNF threads. This made ordering the thread cutting dies real fun!


The resin was applied to the crack with a small chamfer cut into it. The block was heated first with hot water then a gas torch gently played on the block to bring it up to curing temperature. Then the epoxy was applied so that it would run into the crack. The whole process was controlled with a thermocouple temperature meter.


The jeep has now been reassembled and runs well. May be it could take part in a future war film and satisfy the purists!


For more information about military vehicles, equipment and events please see the following links:

Military Vehicle Trust (Cheshire and Merseyside Area)

Military Vehicle Trust (General)