Don's 69 Charger Rust Belt restoration

[mopar4don]

The other side was good

Wow I am tired thinking about all that! 

[mopar4don]

So here are a few pics of the cowl getting undercoated

[mopar4don]

and welded in

[mopar4don]

I also rebuilt the rear quarter window regulator assemblies
This is a before

[mopar4don]

All the parts

[mopar4don]

pic1 I had to remove this roller

pic2  Took a punch and quick hammer strike pushed the pin out of the roller

pic3 removed

pic4 A c-clamp pushed the new roller on

pic5 all assembled

[mopar4don]

The only problem or question I have is with this roller.
The original is on the left, 2 new ones in the middle and right.
You can see how the new ones are longer than the original and the undercut groove is higher than the original so when you snap the retainer in there is about a 1/16 gap.
So that roller can move up and down by that gap amount.
Maybe it doesn't matter? Or do I need to put a washer in there?

[VegasCharger]

.....So that roller can move up and down by that gap amount.
Maybe it doesn't matter? Or do I need to put a washer in there?.....

First off, nice progress on the Charger.

On the repop roller, man that sucks it being off from the original.

May I suggest that maybe use some sort of plastic bushing/washer to fill the gap??

[mopar4don]

.....So that roller can move up and down by that gap amount.
Maybe it doesn't matter? Or do I need to put a washer in there?.....

First off, nice progress on the Charger.

On the repop roller, man that sucks it being off from the original.

May I suggest that maybe use some sort of plastic bushing/washer to fill the gap??

My thought exactly. I was hoping someone else had run into this problem and could comment on if it is a problem.
Maybe it does not matter?

[bakerhillpins]

So that roller can move up and down by that gap amount.
Maybe it doesn't matter? Or do I need to put a washer in there?

Don't you just love this kind of stuff... From my vantage point I'd leave it alone but I don't have the full picture either as I've never done a teardown/rebuild on one.

• One thought - it's entirely possible it's a updated part in later models that was a suitable replacement for the older style.
• Pin length: Can you elaborate on how the pin and rollers are placed in the final assembly? I believe the "lower" roller is fixed on the shaft correct? It may be that the pin length is irrelevant because the "upper" roller is effectively held in place by the channel. Thus the extra length will never carry the roller as it will not slide laterally. So as long as the pin doesn't interfere with any other part of the mechanism it's fine.
• Undercut grove - I see what you're saying but I think that the roller is also wider. It appears that the "top" surface is not flat (tapered down to the shaft) where the OEM part is flat sided. as long as the bearing surface is the same under the roller (can't see but I suspect it is) I wouldn't be concerned.
• Reuse? - If you carry some concern grab some calipers/magnifying lamp and take a quick look at the shaft diameters/condition. My suspicion is that you could reuse the old pins with the new nylon rollers. I'd expect the nylon, which is softer than the metal pin, to be the wearing item. Though if it got filled with hard grime that might cut into the pin.

A few thoughts anyway.  You've done amazing work!

[armor64]

The only problem or question I have is with this roller.
The original is on the left, 2 new ones in the middle and right.
You can see how the new ones are longer than the original and the undercut groove is higher than the original so when you snap the retainer in there is about a 1/16 gap.
So that roller can move up and down by that gap amount.
Maybe it doesn't matter? Or do I need to put a washer in there?

when i rebuilt mine a few months back, the longer shaft didnt matter, it gave the assembly a slight amount of side to side wiggle room, which seemed to make it easier to assemble in the quarter. when it was all lined up and bolted down, there was no extra wiggle, no alignment issues, and it was super smooth.

[mopar4don]

thanks bakerhillpins.

The only problem or question I have is with this roller.
The original is on the left, 2 new ones in the middle and right.
You can see how the new ones are longer than the original and the undercut groove is higher than the original so when you snap the retainer in there is about a 1/16 gap.
So that roller can move up and down by that gap amount.
Maybe it doesn't matter? Or do I need to put a washer in there?

when i rebuilt mine a few months back, the longer shaft didnt matter, it gave the assembly a slight amount of side to side wiggle room, which seemed to make it easier to assemble in the quarter. when it was all lined up and bolted down, there was no extra wiggle, no alignment issues, and it was super smooth.

Ok that makes me feel a little better. knowing someone else had the same problem but that it worked out. 

[mopar4don]

I found someone to help me get the back end of this put together. The 1st thing we did was get the roof skin is on! 

[green69rt]

You can never have too many vise grips, Huh.

[mopar4don]

You can never have too many vise grips, Huh.

Right you are, I've been collecting them for a while and when you do a roof, you need a lot of them!

[tan top]

 

[mopar4don]

I stripped the e-coat off the quarters, deck filler and valance corners, and sprayed with epoxy primer. I took it all the way down to bare metal. I know, I probably could have just scuffed them up but I wanted no possible problems with paint.

[mopar4don]

Then I got some single stage color sprayed on the back side of the deck filler.

I will get color sprayed on the back side of everything I can.
No one else seems to do this but that's what the guy who is helping me suggests.

The quarters will go back to get sprayed color on the back side. But for now they are going back home with me for a wheel well fitment.

Once all the panels are painted then they can get welded on. At least that's the plan

[keepat]

Color looks great Don! Good luck with the paint!
Pat

[Back N Black]

Man you are doing a great job. where are you located in New Brunswick? I'm in Oromocto, would love to see your project sometime.

[mopar4don]

Color looks great Don! Good luck with the paint!
Pat

Thanks Pat

Man you are doing a great job. where are you located in New Brunswick? I'm in Oromocto, would love to see your project sometime.

Thank you for the compliment but I am in Michigan.

[cbrestorations]

While quarters are off spray color on inner structure too

[mopar4don]

While quarters are off spray color on inner structure too

Hey Cris, Yes that is the plan.
The guy that is helping me (THANKS KOLLY) says that's how he does all of his cars. And after he explained it, it all made sense!
I just always thought that epoxy primer on the back side of panels was good enough. And I don't see anyone on these forums putting
color on the back of panels. Or if they are I guess I missed it.

[hemi-hampton]

While quarters are off spray color on inner structure too

Hey Cris, Yes that is the plan.
The guy that is helping me (THANKS KOLLY) says that's how he does all of his cars. And after he explained it, it all made sense!
I just always thought that epoxy primer on the back side of panels was good enough. And I don't see anyone on these forums putting
color on the back of panels. Or if they are I guess I missed it.

You must of missed my post from 2007. I always (usually) paint the hidden areas behind Panels. LEON.

http://www.dodgecharger.com/forum/index.php/topic,35671.0.html

[green69rt]

The only problem or question I have is with this roller.
The original is on the left, 2 new ones in the middle and right.
You can see how the new ones are longer than the original and the undercut groove is higher than the original so when you snap the retainer in there is about a 1/16 gap.
So that roller can move up and down by that gap amount.
Maybe it doesn't matter? Or do I need to put a washer in there?

when i rebuilt mine a few months back, the longer shaft didnt matter, it gave the assembly a slight amount of side to side wiggle room, which seemed to make it easier to assemble in the quarter. when it was all lined up and bolted down, there was no extra wiggle, no alignment issues, and it was super smooth.

Ditto. Also allows some side-to-side movement of the assembly when rolling the window up and down.  Just tried on mine and it does move  bit.