Don's 69 Charger Rust Belt restoration

[mopar4don]

These next pics show the template along the section line and you will see how far off the metal is. The same templates were used for both fenders. NOTICE how the pics of the grey fender were taken from above looking down. And the pics of the black fender were from below looking up.

[green69rt]

I'm going to make a guess and say that if you bought two new AMD fenders and compared the profile of all five (your three and the two new ones), you would find that they are all different.  I bought a left and right for my 69 and compared to a OEM fender and none matched.  If you want them to match you'll have to chose the one to use as the pattern and match the other.  Things may have changed since I bought mine but I wouldn't count on it.

[mopar4don]

I'm going to make a guess and say that if you bought two new AMD fenders and compared the profile of all five (your three and the two new ones), you would find that they are all different.  I bought a left and right for my 69 and compared to a OEM fender and none matched.  If you want them to match you'll have to chose the one to use as the pattern and match the other.  Things may have changed since I bought mine but I wouldn't count on it.

Hi Mitch,
I can tell you that they do match each other. That's why I used the template. I wanted something to compare to, and they may as well be consistent. Unlike Ma Mopar did it back in the day, as you noted.

[orange383]

Very clever using the reference lines. I'll be using that handy little tip on my own Charger! 

[Stevearino]

Don, What I love about this project so far is the amount of sweat equity you have invested. Your ingenuity is refreshing in a store bought world.

[mopar4don]

Time to make a patch for the nose of the drivers side

[mopar4don]

Got the inner patch made

[alfaitalia]

That looks familiar ....! If I had a Pound for every patch I've made for mine I would not have to restore this one...I could buy a restored one!!!

[mopar4don]

That looks familiar ....! If I had a Pound for every patch I've made for mine I would not have to restore this one...I could buy a restored one!!!

Right you are!

[mopar4don]

I had to cut out the bad area in the fender and then use the shrinker to form the outer contour

[mopar4don]

I also added the wrap around shape of the nose to my templates.
Here you can see two more layers that I stapled together. I need this to help me with the shape of the nose and "inner flap patch"

[mopar4don]

In this pic you can see the inner flap and the contour was matched to the outer patch using a stretcher

[mopar4don]

So after fitting the patch, (grind, fit contour, REPEAT, and REPEAT and REPEAT)
I welded it in

[mopar4don]

Once it was welded in I could fit the "inner patch" using the wrap around templates
(I used magnets to hold the patch)

[mopar4don]

So after welding in the nose patch, I noticed a problem in the front profile of the patch
(view as if you were standing at the side of the car)

[mopar4don]

So I made another template from my good fender (view from inside of fender)
pic1

pic2-3 Is the view from outside of the fender

[mopar4don]

No other way but to slice it, and gap it to fit the template

[6pkrtse]

Awesome work as always.

[mopar4don]

Awesome work as always.

Thank you, but I should have caught this earlier!
My mistake was not referencing the horizontal templates!
I should have had vertical lines and marks on my templates indicating that vertical line.
Then I would not have had this problem. But sometimes I learn as I go. (I know, I know I learn how to fix my mistakes)

[keepat]

Don, 
Nice looking repair, I don't look at it as a mistake but more like another step in the restoration.  I know I've added a lot of extra steps in my restoration ;-)
Pat

[BDF]

Nice work 

[Baldwinvette77]

freaking beautiful, man! 

[cdr]

  

[Homerr]

Awesome work Don.

I'm hungry for some beans now.

[mopar4don]

The pass side fender was not as bad, I cut the inner flap from the nose (like the drivers side) and ended up making a tool to hammer out the nose.
(sorry no pics of this process)
I did layout the grid and used the same templates to get the nose shape correct.
I took all fender components and blasted them