Don's 69 Charger Rust Belt restoration

[mopar4don]

Left this bracing in to support the back half of the roof
It will stay untill I get the wheel wells welded to the rockers

[mopar4don]

With the bracing out of the way I could start work on the floor

[mopar4don]

This needs a new section as well as the driver side

[keepat]

Don,
Good to see an update on your charger! With the doorjamb and inner quarter removed there is a ton of room to work on the floor!
Pat 

[skip68]

Looking beautiful.   

[tan top]

  looking good 

[tomonty]

That floor will be a walk in the park compared to everything else you have done so far 

Mike

[cdr]

 

[mopar4don]

Thanks fellas for the encouragement!

Here are a few pics showing how I sectioned in new metal for the floor.

Basically how I did this Is I layed the original in and screwed it down with some self tapping screws.
Then I over layed the white pan and traced around it.
Then I took the black pan back out and cut out the bad leaving a 1/2 for adjustment
Then back in went the black floor, making sure it was screwed down tight. Then I fit in the white pan and trimmed were I needed until I was satisfied it fit, then I scribed around it again. Removed it all, trimmed it to the new line then back in it went, had to to a little trimming here and there. Once I was satisfied with it I tack welded, pulled it out then welded er up!

[mopar4don]

more...

[mopar4don]

more

[keepat]

Great job!
Pat

[birdsandbees]

When are you opening a resto shop? 

[cdr]

again,, AWESOME !!!! you really are going to have a charger when done 

[tomonty]

Like I said, walk in the park. Great job Don. 

Mike

[Homerr]

Amazing!   

[mopar4don]

Here is a pic of the floor after primer.... waiting to go in

[mopar4don]

I have been putting this off,

I need to section out my firewall to bring it back to a non AC car!
For those that don't remember the front clip I am using came from a 69 4 door Coronet with AC.
I decided not to change over to AC, this way it would be like original. (OK, and cheaper)

This took a lot of thought. (need to be sure that I remove some holes, and add others)
So what I did was take pics of an AC firewall and non AC firewall compare the two and fill the small holes and drill out the others.

[mopar4don]

Then it came time to section out and fill the large holes.
What I did was I made a template and traced out both firewalls
(using 2 holes common between the firewalls as an alignment)

[cdr]

excellent!!!

[mopar4don]

Next I layed out were I wanted to cut, then cut it out

[mopar4don]

I then transferred the hole to the template and marked the donor.
Note: the donor section is larger and I included the alignment holes

[mopar4don]

I think you can see the 1/4 drills I used to align the panel in these two pics.

[mopar4don]

At this point I traced the opening onto the donor, cut and fit, and welded her in!

[mopar4don]

Used some All Metal to smooth out the imperfections.... just have to get some primer on