Don's 69 Charger Rust Belt restoration

[Cncguy]

Can't imagine needing that much tire on a street car.

[mopar4don]

Thanks for the comments guys. Looks like I will have a bit of researching to do when I get that far.

[cdr]

Can't imagine needing that much tire on a street car.

I can!!!!!!!!!!!!!!!!

[cbrestorations]

very dedicated build here, you are doing a great job, she will be ur pirzed possession once completed

[Pat1973charger]

Don, I couldn't get te skin I break free at the A pillers and I mangled it a little at the corner. It had a little rust near the seam at the quarter by the drip rail anyway but I was going to patch that. Not sure now what I'll do. Try to repair or replace. I like the dehump idea. Not sure of I will need it as  I plan on running magnum 500s at this time.

[Stevearino]

Always amazing your attention to detail and your determination not to rush things and cover all the bases.

[tomonty]

Hi Don,

As everyone has already stated, amazing work. 

I am in a similar boat as you in that I have an extremely rusty Charger and I would like to put it on a jig like you built. Do you have a materials list or anything for what is needed to build it? And secondly, how did you get the car up on the jig?

You're thread is an inspiration for me anytime I look at my car and think 'what have I gotten myself into?' 

Thanks.

Mike

[mopar4don]

Hi Don,

As everyone has already stated, amazing work. 

I am in a similar boat as you in that I have an extremely rusty Charger and I would like to put it on a jig like you built. Do you have a materials list or anything for what is needed to build it? And secondly, how did you get the car up on the jig?

You're thread is an inspiration for me anytime I look at my car and think 'what have I gotten myself into?' 

Thanks.

Mike

Hi Mike, 
The jig was originally a 4'x8' table that I picked up at the local scrap yard. It was cut in half horizontally then put end to end to give me 4'x16'
It's made from 2x2 tubing with ¼ wall. And has a jack at every leg.

Getting the car on the jig was a little tricky but ended up working well.
What I did was I had the car on jack stands with the jig positioned behind the car.

I lifted the rear of the car with a floor jack and a length of 3 inch sq tubing mounted under the frame rail. (floor jack was in the center of the car)
I removed the 2 rear floor jacks and rolled the jig in under the car as far as I could. I then lowered the car back down onto the floor jacks, and would then repeat the process at the front of the car with another length of 3 inch tubing catching the torsion bar crossmember.

I repeated this process at the front or rear, until the jig was under the car.
It was a little nerve racking but I was careful, and went slow.

Good luck. maybe try using a cherry picker if you can.

[tomonty]

Awesome...thanks for the info 

Mike

[Pat1973charger]

The cherry picker is a good idea, saw some guys using chain falls on one end to their rafters and cherry picker on the other end. The easy way is how i did it, put car on my hoist pulled the k frame and rear end. Rolled the jig under and lowerd the car onto it .

[Stevearino]

If your ceiling structure will take it these chain hoists worked pretty good for my project. You just have to rig some lifting brackets.

[mopar4don]

Ok, now for some of the ugly.

I diced the wheel well up pretty good and started the long process to weld it up.
The gaps were so large I had to use a copper spoon on the back side

[mopar4don]

I did not get a lot of pictures, but at this point I was getting so many welding blow outs, it was driving me crazy!

[mopar4don]

What you cant see in the pics is that nothing was smooth. What I wanted was a nice smooth transition. I wanted it to look like it came from the factory. Thats not what I had...... so I decided I would remove the wavy welded up mess, and patch in a new piece.

[mopar4don]

more

[mopar4don]

I like the looks of this!
Overall it looks much better than all that slicing welded up mess!

[green69rt]

You must have about 200 vise grips!!!!  I'm jealous, I only have about 80.

[mopar4don]

You must have about 200 vise grips!!!!  I'm jealous, I only have about 80.

Yeah and I need another 200 for when I put together the back half of the car!

[Stevearino]

Looks like the right choice putting in the one piece patch. That will save time on the other side now.

[Dino]

You must have about 200 vise grips!!!!  I'm jealous, I only have about 80.

Yeah and I need another 200 for when I put together the back half of the car!

Self tapping screws are your friends.   

[Cncguy]

You must have about 200 vise grips!!!!  I'm jealous, I only have about 80.

Yeah and I need another 200 for when I put together the back half of the car!

Self tapping screws are your friends.   

And Clecos

[mopar4don]

I'm not real happy with the front side of this, but for now I want to go to the other side and maybe try something a bit different.....

[mopar4don]

Here are some good before pics showing the stock wheel house and the crease that will go away

[mopar4don]

Ok this time I started slicing along the crease
Then I hammered out flatening the crease which closing the gap.
NOTICE the white marks. this is what happens when you hammer on that PPG shopline epoxy paint.
I am really impressed how tough this stuff is! it DOES NOT chip crack peel or scratch after wailing on it with a hammer! I don't know if all epoxy primer can take this abuse but I feel pretty good about protection from stone chips on the bottom side of the car!

[mopar4don]

Worked my way up (LOTS of hammering)