Paul Bennett's Custom Mustang V8-Powered 1942 Willys

willys 2 nw

Paul Bennett has put his name to more than 150 top-flight street machines and rods. This Willys he built for himself

This article on Paul's 1942 Willys was originally published in the April 2007 issue of Street Machine

PAUL Bennett’s blisteringly bright red Willys is hoisted to head height. Photographer Peter Bateman is sitting behind his camera under the car’s nose, streaming digital images to a laptop computer. My laptop is also on the bench but mine has a blank screen. Just like my overloaded brain. I’m staring up into the Willys’s detailed underside thinking: “Where do I start?”

1942 WillysMaybe the best place to begin is with the who, the what and the how. And let the pics explain themselves. Paul Bennett is one of Australia’s most prolific street machine builders, with involvement in more than 50 magazine cover cars. His touches can be as simple as a doorhandle shave, or as comprehensive as a total floor and chassis replacement, body re-configuration (low-lid and two-door conversions are a specialty) or a re-power with anything from a rotary to a blown big-block.

Gallery: Borgward Goliath by Paul Bennett

1942 Willys frontDon’t for a moment think his workshop is littered with greasy mechanical off-casts or panel-less bodies, either, because you need to book in to be built by Bennett. Oh yeah, and his paint and distinctive graphics are hot too. In short, there’s little this modest ex-Canadian — he’s been officially Aussie for 25 years — can’t or won’t do.

Interview: Street machine builder Rex Webster

1942 custom Willys sideThe base colour is a punchy custom Bennett Red with another 150 hours (or a month full-time) of intense concentration required for the graphics

Beginning with a Rodworks unsteeled ’glass body, Paul planned and built this Willys from the outside in, for someone else.

“It was originally a customer car with a blown and injected big-block,” Paul explains. “It was almost a drag car in the way it was built; I did it light and super-strong with a chrome-moly chassis and big brakes.”

1942 custom Willys bootMost of the wiring and control systems are mounted in the rear of the car. The fuse and relay box is installed at the top edge behind a secret panel between the hinges. It was tight, but Paul managed to fit in a huge 90-litre fuel tank giving the Willys a cruising range of 600km+

His build shots show a dinosaur skeleton, with ribs rising from twin spines of 150x50mm roll-formed rails. Despite the requirement for strength, the bones were shaped to minimise intrusion by the rollcage and allow the car to be street driven. It’s smooth too, with no squared or mitred corners; everywhere this chassis changes shape it’s smooth.

1942 custom Willys engine bayPaul weld-closed all redundant external holes in the block and transmission case, and plated between the ribs of the block. Rocker covers were heavily reworked and smoothed after the oil filler was relocated. The throttlebody was cut and shut to follow the angle of the valve covers. Engine cover and extractors are Paul’s work

“I laid it all out to maximise interior room,” says Paul. “To get the car to sit so low was a challenge. I built it to the stage where it was rolling, with the mechanicals placed and tinned. It took two of us — me and my offsider, Blake — 12 weeks to get most of it done.”

1942 custom Willys stripesBennett’s finely detailed graphics are unmistakable. Paul has wanted to drop a Dreamtime theme onto a car for some time and the Willys was the perfect opportunity

However, the original owner couldn’t see the project to completion.

“I could see it coming,” Paul says of the bail-out. “I told him that I wanted first option on the car if he wanted to sell it. Eventually I bought it as a roller and he kept all the mechanicals. The foundation was fabulous — and I knew exactly what was there!”

1942 Willys rearThe skin is fibreglass but heavily modified. Paul added apertures for weather seals, rounded the doors, coke-bottled the steel running boards, flushed the screens, suicided the doors, hid the latches and reshaped the bonnet and front guards

The components in the rolling chassis include an off-the-rack IDIDIT front end — ADR approved with HQ Holden geometry — fitted with Castlemaine Rod Shop dropped spindles to dump it an extra couple of inches.

1942 Willys interiorCustom seatbelts mount to the hidden B-pillar chassis hoop. The entire cabin floor and rear wall is sheet steel, with a section between the chassis rails behind the rear seats laid back to take advantage of room above the rear axle

Paul designed the rear so that the arms present no visible threads although they’re adjustable. Total suspension travel is seven inches, providing a terrific blend of stance and streetability from the Air Ride Technologies four-way solenoid controlled self-levelling airbags. Huge discs — 390mm up front and 430mm rear — are bigger than a V8Supercar’s anchors and are clamped by six-piston Alcon calipers at all four corners.

1942 Willys interior frontThe all-steel mirror-image dashboard wraps into the doors. Its design allows the car to be converted to left-hand drive with ease. The controls for air and power windows hide behind a central panel. The shifter for the four-speed auto was heavily modified to work with the instrument cluster and management system

“I thought it would make a great Pro Touring car,” Paul says of the unfinished chassis and body combo. “I wanted it to go, stop and steer with the same sharpness its appearance suggested, with no empty promises. I’ve always said if I built a hot rod for myself it would be a Willys. They just have such an elegant shape, with the fat-fendered guards and all.”

1942 Willys door trimSydney’s All-Trim was responsible for the headlining and Jap-import seats, and assisted with the remainder of the interior trim. The trim material is mustard leather and suede applied over Bennett-built fibreglass and sheet-metal shells and frames. Leather covers the floor too

The car’s original blown big-block brief was all grunt and little comfort, but Paul’s Pro Touring plans called for more luxury, more refinement and a late-model electronically managed driveline.

“I wanted a user-friendly, gentleman’s hot rod,” Paul explains. “I reckon it’s the future. Jump in, turn the key and drive to wherever you want.”

1942 Willys exhaustThe sheet-metal nine-inch housing was built with assistance from Terry Cartwright. It’s home to MW 40-spline axles, carrier and pinion support. The use of a separate cross-axle suspension bar below and behind the axle housing not only braces everything but allows a lower ride height without restricting suspension travel

A suitable combination of output, technology and aesthetics led Paul to choose an all-alloy 4.6-litre Ford DOHC US-market Mustang V8. He wasn’t too worried about the bits you can’t see and didn’t fiddle with the internals of the 225kW mill. Instead, his efforts went into making its appearance worthy of the Willys. He wanted an auto and Ford R&D in Detroit recommended the R4100 as a tough and reliable ’box. However, a slushy was never hitched to this tune of 4.6, so no factory management system or wiring loom was available. Superior Custom Classics in Florida supplied the advice and electronic hardware to make it all work.

1942 WillysSuspension is built around a four-way self-levelling Air Ride Technologies system. The rear uses simple four-link geometry (adjustable) with a track locator. Its ‘Z’ shape requires less room than a Panhard bar or Watts link, very important with the minimal space

The list of luxuries Paul wanted also presented some hurdles.

“Just trying to find space for all the electronics was a challenge,” Paul reckons. “The amount of shit that’s in there to control everything is just amazing. There’s engine management, transmission management, cruise control, electric windows, the airbag controls — just horseshit!” Paul says. “It also has remote start, an alarm system, three-speed wipers, air con with the heater and demister; solenoid doors with central locking. Every component had to have a home. It had to fit somewhere.”

1942 Willys undersidePaul is particularly proud of the cloverleaf detail in the rear crossmember. The short tailshaft and the dual exhaust pass through ‘leaves’ in the aperture. With no room in the car for an air tank, the left chassis rail is the pressure reservoir for the airbag suspension. Apart from the trans cooler, brake booster and rear suspension Z-bar, the chassis is mirrored side-to-side

Another headache was making it all work with the Dakota Digital dash. “What a headf***!” he says. “I wanted to do something that had never been done before. I had to make a shifter to recognise all that, then send info to the dash display. I wanted it to be easy for the driver but it certainly wasn’t easy for me. I was learning on the run.”

1942 Willys undersideEvery change in the chassis profile is curved; there are no sharp edges. Nothing hangs below the level of the chassis — the Bennett-built engine and gearbox sumps are level with it and each other. The engine is behind the front axle line for good balance. Mounts are works of art

A bloke by the name of Sideshow — a Sydney-based retrotech wiring guru — sorted out most of the spaghetti.

“I bought a harness from Superior Custom Classics,” says Paul. “Sideshow made the harness pretty; he made it all fit and be ‘sight-unseen’.”

1942 Willys undersideThe radiator is a self-made two-row aluminium dimple-core laid back to allow a larger unit to be installed. The undersides of the bonnet and guards are as smooth as the topside

Getting the body blemish-free and tight is an obvious car-crafting process but an enormous amount of work went into the things you don’t notice as well. For instance, the bare body arrived without any mounts for door rubbers. Paul had to build lips within the door apertures to seal out the draughts. He also laid back the prominent Willys nose and peaked the bonnet and guards with a barely visible line for a little more definition. The door corners were rounded and the Bennett-built steel running board edges are now Coke-bottled rather than straight. The car’s custom flush-fit glass required special attention. The tail-lights are flush-fitted too, and sealed to the car with clear-coat paint.

1942 WillysSuspension is built around a four-way self-levelling Air Ride Technologies system. The rear uses simple four-link geometry (adjustable) with a track locator. Its ‘Z’ shape requires less room than a Panhard bar or Watts link, very important with the minimal space

Two hours after turning my computer on, I’m still finding details and tricks in the car’s underside and haven’t even begun looking at the rest.

Does Paul have a favourite detail? He thinks for a couple of seconds after I ask the question. “Nah, it’s a complete package. The paint, interior, driveline … I’ve detailed everything 120 per cent. It’s homogenous. No one part of the car is better than any other.”

Willys platesThe rear number plate resides on a flip-down hinge driven by an electric motor like a pop-up headlight. It’s actuated when the ignition is on but has an override for when Paul needs a bit of extra ground clearance, such as loading the Willys onto a trailer

The build is dedicated to Paul’s dad. “I had the car well underway in paint and had laid out much of the artwork when I lost my dad,” he says. “It was in September last year. The Aboriginal Dreamtime theme was something that I’d wanted to do for years but I never found a customer with the guts. This was the perfect opportunity. I had Dad’s words in the back of my head: ‘Always do exactly what you want to do. Do things as you please.’”

PAUL BENNETT
1942 WILLYS

Colour: Bennett Red

POWERPLANT
Engine: Mustang 4.6-litre DOHC V8
Manifold: Relocated throttlebody
Exhaust: Bennett-built 17/8-inch extractors, three-inch twin-cat system
Radiator: Bennett-built two-row dimple core
Sump: Custom

TRANSMISSION
Gearbox: Ford R4100 four-speed auto
Tailshaft: Fabricated chrome-moly
Diff: Sheet-metal housed nine-inch, MW internals

BENEATH
Front: IDIDIT independent with CRS drop spindles (f); four-link Z-bar (r), Air Ride technologies adjustable airbag suspension (f&r)
Brakes: Alcon six-piston calipers on 390mm (f) and 430mm (r) rotors. Handbrake on driveshaft

INTERIOR
Seats: Buckets
Trim: Mustard leather and suede
Gauges: Dakota Digital
Wheel: Colorado Customs
Sound: Kenwood boot-mounted stacker with three 6x9s and two six-inch speakers

ROLLING STOCK
Wheels: Colorado Paradox, 18x7 (f), 20x12 (r)
Tyres: Pirelli P-Zero Nero, 225/40 (f), 345/25 (r)

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