Don's 69 Charger Rust Belt restoration

[cdr]

  DON

[mopar4don]

Thanks guys for the color chips, When I get closer to being finished with the body work, the color will get more thought.
But right now that seems a long long way away!

Hi CDR

[mopar4don]

Next I pulled the cowl off, and found another mouse nest and more rust damage around the base of the a-pillars 

[CornDogsCharger]

Looks like you're making great progress!  Keep up the great work.  I love seeing rough and rusty cars getting saved and put back on the road!  The rustier they are, the more I appreciate the work that goes into saving them. 

Justin
"CornDog"

[mopar4don]

What a mess, definatly worse than I thought when I first looked at it! 

[tsmithae]

It's funny how they do that to you... 

[bill440rt]

For a "beginner" I think you're doing a mighty fine job! 

[mopar4don]

Thanks everyone for the encouragement! Corndogscharger, tsmithae, bill440rt.
I think I'm gonna need it!

[charge69]

You got a long way to go and many frustrating hours of work yet but, you have shown you have what it takes to complete this project!  Just keep your head down and keep the faith completing a little at a time and you will be rewarded with a beautiful Charger of your very own!

Good luck and do not let it get you down. If you feel like "burnout" is taking over, step back and let it sit for a while and regain your desire to get it done. It took me and my friend 5 years to get mine to where it is with a few "breaks" and many frustrations along the way.

[six-tee-nine]

Next I pulled the cowl off, and found another mouse nest and more rust damage around the base of the a-pillars 

Is it hard to pull the cowl panel? I mean if you drill the spotwelds does it deform alot cause of the bonding adhesive they used?
I'm thinking of pulling the panel because i also have probably alot of rodent crap and nests in there.
Hell I even have rodent nests in my frame rails....

I would like to reuse the panel if possible so I can clean it out blast it paint it and put it back on.

[mopar4don]

Next I pulled the cowl off, and found another mouse nest and more rust damage around the base of the a-pillars 

Is it hard to pull the cowl panel? I mean if you drill the spotwelds does it deform alot cause of the bonding adhesive they used?
I'm thinking of pulling the panel because i also have probably alot of rodent crap and nests in there.
Hell I even have rodent nests in my frame rails....

I would like to reuse the panel if possible so I can clean it out blast it paint it and put it back on.

six-tee-nine,

I would say if you have the patience and the willingness, then anyone can do this.
After drilling the spotwelds you just have to be careful when prying the cowl off as that seam sealer they used does want to stick.
The biggest thing I can say is to fight the urge to want to rip it apart, If you take your time, you can do it!

[tsmithae]

  You've obviously gpt the patience, talent, and ambition to get it done!

[gers1968rt]

 Looking good so far, Don.

[tan top]

   ... 

[mopar4don]

Let me catch everyone up a bit.
Last winter I bought and worked on dismantling a 1969 4 door Coronet that I basically got for the rear frame rails and floor pans. If needed, I would also be able to use the
inner fenders,
inner rockers
outer rockers (I would need to patch the cutouts for the rear doors)
torsion bar crossmember
upper and lower cowl
and the rest of the entire front clip if needed.
Another thing this car did was give me the opportunity to "learn" how to take these cars apart!

[mopar4don]

more

[mopar4don]

Here are pics of the rear frame rails, and front floor pan. The floor pan will need to be patched in the drivers side foot well area.
The frame rails are perfect! NO rust or rot anyware!

[mopar4don]

Decided to brace up the back side of the car in preparation for rear frame swap.

[mopar4don]

more

[Old Tired Rebel]

Do you have to use a jig to do all this? My Charger is from Mich and the frame rails seem fine. I am hoping I don't have to pull my Cowl out a lot.

[tsmithae]

Not necessarily, I did mine with copious amounts of bracing and measuring. Jig would be the way to go if you have the means.

[Old Tired Rebel]

Not necessarily, I did mine with copious amounts of bracing and measuring. Jig would be the way to go if you have the means.

Thanks

[mopar4don]

Do you have to use a jig to do all this? My Charger is from Mich and the frame rails seem fine. I am hoping I don't have to pull my Cowl out a lot.

Hey Rebel,
A few reasons why I used a jig,
I had NEVER done anything like this before, and being a beginner I did not want things moving around! (I don't know the tricks, and what I can and cannot get away with)
I knew (at minimum) I had to replace the rear frame rails, inner and outer rockers and the front torsion cross member.

If I were you, I would be absolutly sure there is NO debris inside the cowl. Mice love this area! I found nests inside the cowl, front and rear frame rails, and rockers. If I would have had a headliner in I'm sure there would have been one there to.

Hope this helps.

[Old Tired Rebel]

It does help Thanks.

[mopar4don]

I've decided to replace the entire front clip with the donor clip from a 69 4 door Coronet.
I had too many issues with the Charger front clip, so I decided I would be better off to use this really nice Coronet clip!