My '68 Charger restoration

Here is my midlife crisis car, a gift from my wife for my 30th B-day. Granted, I'm only 30, but my wife says I don't get to buy a red Corvette when I turn 40, I have to build my crisis car myself. This is what she bought me, explaining that it will take 10 years to finish, so I'd better get started now. It is a no frills 383/auto, and as such, I can do whatever I want to it rather than worry about #'s matching anything like on my '67. This post documents everything from the purchase date of January 15, 2010 through about June 1.


Here's the pics from the craigslist ad.

http://img.photobucket.com/albums/v227/67Charger/CIMG3340.jpg

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Here's some more detailed pics once I got her home.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4010.jpg


Sitting with my '67

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Mexican registration stickers from the '70's

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4106.jpg


Excavation has begun. Hood is trash, as is the RF fender. I removed them for better access to the engine and to begin assesment of the frame.

The engine cranks and tries to fire, but more exhaust was coming out the valve cover than the pipes, so I've got a burnt piston or something equally bad. No bother, I just won't mess with it anymore and move on to the body for now. I've unbolted the K-frame and loosened the control arms, I just need to ditch the t-bars and trans crossmember and the K-frame assembly will get pulled. Hopefully tonight I'll get to do so.

A rough life in the Mexican desert has led to massive amounts of silt in the frame and body work, holding moisture and causing rot. The car had a vinyl top that failed and caused rust all around the roof, so it will need replacement. Lower quarters, rear decklid, rear filler, sail panels, package tray, trunk floor, all shot. Ironically, the floors are perfect.

I'm just moving my way back and excavating before I cut metal and blast, patch and replace.

http://img.photobucket.com/albums/v227/67Charger/IMG_4086.jpg

Rust in the lower A-pillar

http://img.photobucket.com/albums/v227/67Charger/IMG_4099-1.jpg



K-member assembly out. What a pain!

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4108.jpg

I sliced the roof skin off to see what was underneath. All I can say is WOW. Stupid vinyl top was murder on the roof. I can patch a lot of it, but I'll need some actual parts to splice in for the bad areas.

I had already counted on a new roof skin, drip rails and rear frame bow. It's the sides that I need to start working on. Once I get the dash out, I'm going to sandblast the whole body. I'll picture frame the quarters that will be getting replaced so I can blast behind them but not lose all the structural integrity until I'm ready to replace the panels.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4123.jpg

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Rust by the bumper mount

http://img.photobucket.com/albums/v227/67Charger/IMG_4059.jpg


Due to the extensive rust in the roof area, I've located a complete roof assembly (skin and all) that I could either install as a unit or use for parts, and a few parts cars that I can simply get the individual panels that I need to reconstruct the roof area. It's a bit beyond the hand fabricated patch method in a few areas. I'll need to get the actual factory panels. The area above the rear passenger windows is nearly gone.

On a side note, what are these numbers stamped in the flange where the 1/4 meets the roof?

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4131.jpg

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Got the dash out... No surprises underneath, just tons of dust and dirt. I also removed some of the bad 1/4 panel, and saw just what I suspected. Dirt and crap has built up in the bottom of the panel joints and rusted them out. The dirt in the last pic is a typical example of what I have been finding.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4156.jpg

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Got the firewall completely stripped, no nasty surprises there. I was also pleasantly surprised thet the rear package tray is actually fine, it is just the lower window gutter that is shot. One less panel to R&R. I called AMD and asked them if they were planning on doing A-pillars, and they said yes, but about a year out. I should have this thing completely stripped and ready for blasting in a few weeks. I also took the time to clean out another bay in the garage for epoxy coating so I can get some of the stuff moved out of the bay the Charger is in and get some work space back.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4206.jpg

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I have just about everything from the latch post forward stripped. I just need to remove the brake lines, tail lights and trim, rear axle and the 1/4 window assemblies, and it will be ready to blast.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4309.jpg

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More pics coming soon!

not one link works.

wow great car I love those 68's , great progect and good luck .

it looks like a northern (salt bathed) car. good luck and God bless you.

Wow, the roof area is far worse that I could ever have imagined! Much more so than my GTX.

it is definetly a fixer-upper.but worth it.there is no where to go but up and you only need to stop when you're satisfied.

That hood modification looks like it was done by a fan of the Oldsmobile 442.
The floors appear to be quite solid in the photos,in comparison to the rest of the car.....bonus if they are.

Quik progress, remember the wife said you have 10 years to build it.:rolling:
Nice project and I am sure glad my roof was not in need of any work. Bummer that you are accross the country, I have a leftover non a.c. cowl section, that would work nicely for you. You will see #'s like those on every stamped sheet metal part on the car, part #'s is my guess. `68 Chargers are my favorite, thanks for saving this one and good luck. You can bet I will be watching this one!:grin:.

I admire you willingness to tackle this project! Some would declare it salvage by their on admittance on other threads but some of us including yourself know better and we know what it will be in the end. Hammer On!!!!!!!!!!!!!!

I admire you willingness to tackle this project! Some would declare it salvage by their on admittance on other threads but some of us including yourself know better and we know what it will be in the end. Hammer On!!!!!!!!!!!!!!

I fully agree! I am glad this car will come back to life one day,also love the 68'S and am very interested in watching this unfold!

Floors are solid, firewall is good, I have an upper and lower cowl plenum, front right frame rail, A-pillars, and a roof frame for parts, everything else I need is being reproduced except the door hinge column/panel.

The rear axle is out and it is down to removing the rear interior panels and the taillights and it is ready for it's first phase of blasting. I'm planning on windowing the original quarters and leaving them on so I can blast behind them without losing all the structural integrity until I have the new ones ready to go on. I'll post current pics later today.

Floors are solid, firewall is good, I have an upper and lower cowl plenum, front right frame rail, A-pillars, and a roof frame for parts, everything else I need is being reproduced except the door hinge column/panel.

The rear axle is out and it is down to removing the rear interior panels and the taillights and it is ready for it's first phase of blasting. I'm planning on windowing the original quarters and leaving them on so I can blast behind them without losing all the structural integrity until I have the new ones ready to go on. I'll post current pics later today.

nice plan can't wait to see more pictures

Nice, again, I love seeing this kind of massive surgery!

Here's a few shots of the roof, the replacement cowl, and underbody. Frame rails are good, but the back if the rockers took a pounding from accumulated silt retaining moisture. This thing spent at least 25 years in the Mexican desert in the Mexicali area. There were more "jimmy-rigs" on this thing than I've ever seen in my life combined. I pulled a rolled up newspaper out of that hole in the rocker behind all the bondo. It was a Mexican paper dated '99, and the windshield had a series of Mexican registration stickers dated back to 1975.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4814.jpg

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fantastic

Tonight's progress - One pitted cowl removed and a metric butt-load of crap exposed. NASTY! What I find most disturbing is the fact that I had already vacuumed it out "good enough" before even considering removing it for replacement. I cannot even imagine what a disaster that would have caused later on.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4854.jpg

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I'm suprised those vent rings on the lower cowl even still exist!. Do you have doner parts for the inner rocker assemblies?. Looking good on the progress, great pics.

If you finish this project before 10 years do you think your wife will buy you another car that needs more work? I wish I had your abilities with bodywork. It will be awesome when done. My favorite Charger model year.

Dude, get that car to your Media Blaster! I promise, it's the best $$$ you'll spend!

Donny - I have a full-tilt sand blast setup - 175 cfm I-R compressor, 30 gallon pressure pots, Bullard forced air system, and 75 TONS of #90 silica. Since none of the remaining sheetmetal will be in danger of warping, I'm heavily considering doing it myself to save the $$$ for parts. Otherwise there is a media blast outfit about 4 miles from my place.

Any compelling arguments to spend the $$$ for a media blaster rather than do it myself?

And I thought my car had rust issues!! holy crap!!

Yea Donny :tongueflap: (couldn't help myself)

I don't think any of us knew your inventory. I could see some of your talents on the roof work and I am in envy of all that I have witnessed on this site that have the time and patience to resurrect any of these cars in this condition. Hats off to ya!:tiphat:

thats exactly why i always hate hearing someone say its a parts car only its not saveable. anything is saveable in the hands of the right person. heck the guy that i got a lot of my missing parts for my car has over a dozen maybe even 2 dozen old mopes that he thinks are only good for parts and almost everyone of them could be restored if someone had the skill and wanted to spend the money

No. You have a good plan and set up! I erred assuming you don't have this sort of equipment; my mistake! However, most people don't have this set up. Pics...lots of 'em! You can use sand and not warp sheet metal, the dangers of sand is enormous amounts of free silicas are released, and sand is not as good an abrasive as A.O.

Quik progress, remember the wife said you have 10 years to build it.:rolling:
Nice project and I am sure glad my roof was not in need of any work. Bummer that you are accross the country, I have a leftover non a.c. cowl section, that would work nicely for you. You will see #'s like those on every stamped sheet metal part on the car, part #'s is my guess. `68 Chargers are my favorite, thanks for saving this one and good luck. You can bet I will be watching this one!:grin:.

The left is usually odd numbered and the right is even. The left is always the highest number if I remember correctly.

No. You have a good plan and set up! I erred assuming you don't have this sort of equipment; my mistake! However, most people don't have this set up. Pics...lots of 'em! You can use sand and not warp sheet metal, the dangers of sand is enormous amounts of free silicas are released, and sand is not as good an abrasive as A.O.

No "err" involved, most people don't have acces to that type of stuff. As far as the silica goes, though not as good, I have more of it than I know what to do with. Do you think I should buy some aluminum oxide for the bad areas and burn the sand on the largely undamaged parts? I'm planning on blasting the body next Saturday.

What about a chemical dip and e-coating?

With sand being so cheap, but the risk so high (Silica), and, sand not being designed to cut like A.O., my adage is 'why use it'? But, with a pressurized helmet, good air, have at it, sounds like a plan.

Chemical Dip and E Coat; great, but, who does it? The cost to start up is so high, the market so limited, and the municipalities would tear you up on this and that regulation on this toxic brew you'd have to keep on hand. But, from what I understand, it gets on every nook and cranny whereas I could only hope to be that thorough in my Media Blasting.

Well you are right on the that it is costly and there are limited people to do it. The "local" place I go to is 40 miles from home in Franklin, WI. Restoration Specialists, they do a whole car for $3500 thats an initial dip, you do your body work and they dip it again and then e-coat it. I use them for minor parts and parts I want to strip without the hastle of wire brushes and methyl ethyl dichlorinate. One downside to the dip and e-coat is that you need to put seam sealer EVERYWHERE! I was told not to do it because it would eat the seam sealer out of the car but, hell in my opinion it would be better than dealing with 30lbs of sand falling out of the rockers everytime I put the cut-off wheel to the shell.

If you just put new rockers on it, then, there would be no material falling out! :)

:skeptical: Well my Charger didn't need rockers, but each car has been oxidized differently. The media blaster didn't do a good job of cleaning it out.

Yeah, there won't be many areas left more than one panel thick by the time it is fully cut for blasting. Had company over last weekend and this weekend is my anniversary, so the car will hae to wait, but I'm continuing to collect and prep replacement panels in the mean time.

Rocker panels are very difficult to get all the media out of after blasting.

damnnnn Man good work !

i am still waiting for next pic :-)

your wife doesn't care for you much does she?, I have a rust spot in my trunk the size of a dime and I'm "freaking out"?

I guess I'm spoiled being from L.A.!

but your also in California, how/why on earth did you get such a rusty car?,..you must love a challenge!

...why? A few reasons. First, it didn't deserve to die such a pitiful, cancerous death after having been abused for decades in the Mexican desert. Second, I do enjoy a challenge, and my '67 is all but finished and has been for years. Third, and most importantly, it was in my starting price range. I know I'll have more in it than it's worth in the end, but that was never really a consideration. I want to build it how I want it, and never have to worry about preserving the #'s matching stigma. She'll love me for saving her from the grave.

...why? A few reasons. First, it didn't deserve to die such a pitiful, cancerous death after having been abused for decades in the Mexican desert. Second, I do enjoy a challenge, and my '67 is all but finished and has been for years. Third, and most importantly, it was in my starting price range. I know I'll have more in it than it's worth in the end, but that was never really a consideration. I want to build it how I want it, and never have to worry about preserving the #'s matching stigma. She'll love me for saving her from the grave.

I would love to see the car when it's done, I remember cars that had minor fender benders back in the late 70's/early 80's, that were sent to the scrapyard,it made me sick!

bringing this car back is a good thing for sure,especially being a '68 (my favorite year charger)

if you can do it ur self then go for it.

man you give me hope lol. keep the updates comeing

Kudo's on manning the reign's of resurrection of your Charger! Keep up the good work.

Wow I had no idea there were other people who cared to save Mopars even when they are worse for wear. Before I heard of nothing but parting out a mopar like yours.

Moving Day!

I'll finish trimming bad metal and removing the rear windows at the shop. I happened to have the crane for the day so I figured I'd make use of it.


Sitting with her older sister...
http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_4996.jpg


How else do you load something in this condition?
http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_5002.jpg

WOW, 67, you are da man for savin' this old girl!!! :app::beerchug: 68 is my favorite year for Chargers.

Cover up them stickers when you paint, it's cool when you get to have history like that... :cool:

Now there is something you don/t see everyday!.

i'll bet the neighbors were talkin' about that for a couple days.

426: there's a few of us here that save the formerly un-savable!
67: Moving...to where? New shop, new house, bigger shop, smaller house (that's the right way to do it) :)

:grin:

I guess I should have specified... To the crane yard where the blaster is set up. It's the family busuness so I have free reign of the facilities afterhours and on weekends. Now that it's there I can "carpe diem" whenever the free time arises and get right to blasting. Moving it there was a big hurdle. Now it just needs some final prep and it can get moving again. I picked up a rear inner/outer rocker section that will replace the 18" of rotted rocker on the passenger side, and a drivers side door hinge/side cowl panel. Progress is being made in the acquisition department.

:tiphat: to you for such a courageous endeavor, I hadn't seen a wide angle shot of the Charger.

Most non-car people would have the attitude of ......ahh screw it, it's just an old car put it through the crusher.
But the thing to remember with projects like this is.....Limitations exist only in the mind.
Anyway......i'm off to an antique furniture fair to tell em they should put all that old shit through the wood chipper.

Been a while... ...but getting back on track.

I have been very busy with the '67 for the last few months. My dad and I ran the Nevada Open Road Challenge and the Silver State Classic in it, and it needed a lot of parts swapping and road-race tuning. For those of you not familiar, http://www.sscc.us . Either way, I'm getting back onto the '68 this weekend and next. I've bneen collecting lots of good metal for R&R, but haven't gotten any of the blasting done.

Soon...

Here's a pic of the '67 in it's road race form, and one of my competition in the 125mph class.

http://img.photobucket.com/albums/v227/67Charger/IMG_5635-1.jpg

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Very cool! What a transformation for the 67. I take it your going to wait till it cools off a little bit before you go out and blast the 68.

Very kool!, looking forward to more progress on the `68.

Your a good man to bring this car back to life. You have a lot of work to do, but it will turn out great. It'll be worth it in the end.

Sand blasting today, but the recent rain got into my supply so I'm fighting moisture clogging the flow. I may not finish today, but it is finally geting going again. Pics will be up later.

Man you got some serious cancer on this one...It,ll be nice when it,s done...It,ll even be faster than the corvair in the garage!!
Petty Blue 67 GTX

As promised, pics...


I blasted until the sun went down them shot all the bare metal with PPG DP50LF Epoxy Primer.

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Been too long since I've been able to get back to her. If the rain lets up I'll finally be able to get back to blasting. I've got a week off between the Holidays.

Looking good already. Is that from using sand or Aluminium Oxide?
From the weather reports, I hope you have your rubber underwear on there.

your wife is a good girl, buying you a car to fix. good luck with it. looks like your fixing it the rite way

Wow those pictures are amazing. Especially the cowl ones. I bought a Louisiana barn find parts car for my 68 charger that was off the road for 30 years. It looked like every mouse or whatever was living in it for decades. Nest and crud packed the A/C ducts, heater box, cowl, seats, and behind every interior panel – everywhere.:BangHead: Structure was totally shot but most of the bolt on sheet metal and the forward parts of the quarters were ok. Keep up the good progress!

Looking really good on your 68 Dan, i just love the pic of your 67 lined up with all the (snobby i assume):sigh: sports cars! joe

Looking really good on your 68 Dan, i just love the pic of your 67 lined up with all the (snobby i assume):sigh: sports cars! joe

Thanks... I equate it to bringing a P-51's supercharged V-12 Allison in a Model-A to the 2011 Indy 500. Yeah, it CAN be done and have a great time doing it and embarrass some high dollar rigs in the process.

As far as the '68 goes, I just ordered up some sheetmetal from AMD and did some horsetrading for a good fender. I'm hoping to finish the rest of the chassis blasting here shortly. I had my one good fender along with a spare hood for the '67 (needs a scoop for drag racing) media blasted and should get them back Monday.

yeah, flow of media is an issue, or, could be an issue if you have a non-screw compressor. I'm very aware of flow clogging, it's only moisture that affects it; if you have a screw compressor, and a good moisture trap, you won't have any issues; at least I don't have any, and I've blasted in the pouring down rain (rather, the compressor is out there in the rain). Pics/car looks great!

My rain issue is due to the fact my sand is outside and uncovered. Seems to be drying outfairly well. Now it's just getting the time to do it. I didn't get the week off between Christmas and New Year that I thought I would.

i admire your willingness to save this gem.most wouldnt think of it.maybe you could ask AMD to sponser you.

Did some more blasting last weekend. I tried some stuff called SharpShot, MAN that stuff was aggressive. Back to silica for me. Found some new holes in the rear tail panel and valence, but not sure if it will be repaired or replaced... Pleasantly, the trunk drop off on the drivers side is fine, and the floor continues to be flawless.

Cool! Never heard admiration for Silica like this before, other than the way it cuts? Bravo! Pics?

My blaster setup
http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_6507.jpg

Swiss Cheese rocker
http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_6504.jpg

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has the rest of the car been as bad that you've found? That rust in the door pillar,if the car had been sitting any longer b4 you found it,might've been a lost cause,but glad you're bringing it back.

You got your hands full partner......Impressive project!!

Post winter update.

Finally... After a pending rain storm forced me to hide the car in a 40' shipping container to keep the bare metal from rusting again, I pulled her back out last week. The blaster has been busy for the last few weeks, but I may be able to squeeze in some time this coming week. The hard part is finding room to safely store (in an organized manner) all the parts that are coming off.

Lately, I've been tied up building a car for my dad to run the higher speed brackets at Silver State, but I really don't think it can be done in time. As a backup plan, I've been converting my '67 back from drag to Silver State trim. Last night I welded up the new mounts for the Hotchkis 1 3/8" front sway bar that replaced the factory wet noodle bar. I got the dropped spindles installed and am working on fabricating an air dam for the front. I scored a few deals at Spring Fling for the '68.

Today is the first I have ever looked at this thread. I have only read the original post in it but after looking at the pics in the first post I have to say that I think your wife doesn't like you very much.:bootyshake::icon_lol:

Today is the first I have ever looked at this thread. I have only read the original post in it but after looking at the pics in the first post I have to say that I think your wife doesn't like you very much.:bootyshake::icon_lol:

Not a good road to go down.:nono: LOL

Finally got some time with the car today. Fully windowed out the quarters and undid most of the panel junctions that had rust between them like the 1/4 to trunk rail joint and the bottom of the door pillars. Final blasting should happen this week then finally some metal may start going back on.

I'll get pics up as soon as I figure out how to get them out of my phone without the cable.

As promised, an update. I'm trying not to remove entire substructure panels, but rather splice in good for bad to hopefully preserve factory fitment since there will always be other pieces holding the alignment in check. The trunk floor will remain and the bad center section clearanced out for a custom rectangular cell mounted midway through the floor for added clearance, but will still fill with the factory filler.


Drivers Side behind the 1/4. No unpleasant surprises
http://img.photobucket.com/albums/v227/67Charger/IMG_6982.jpg
http://img.photobucket.com/albums/v227/67Charger/IMG_6983.jpg

Trunk extension survived, will need minor pin-hole repair.
http://img.photobucket.com/albums/v227/67Charger/IMG_6984.jpg

Exposing the trunk rails to salvage them and the stamped VIN
http://img.photobucket.com/albums/v227/67Charger/IMG_6985.jpg
http://img.photobucket.com/albums/v227/67Charger/IMG_6986.jpg

Passenger side was a little worse. I have a new section of rocker to replace most of the missing area without removing the ENTIRE rocker.
http://img.photobucket.com/albums/v227/67Charger/IMG_6987.jpg
http://img.photobucket.com/albums/v227/67Charger/IMG_6988.jpg

Door hinge post. Going to splice in new (donor car) piece.
http://img.photobucket.com/albums/v227/67Charger/IMG_6989.jpg

Front P/S frame rail. Needs more cut away. Have donor rail, just determining the size of the splice.
http://img.photobucket.com/albums/v227/67Charger/IMG_6990.jpg

Looks like it's getting away from you bro! However, I know that feeling myself all too well! However, I don't visit there too often anymore.

How the hell did that trunk ext survive??

That's crazy!!

looks like you are making great progress, keep it up!!.

It's all good, Donny, just need time. :) Nothing I wasn't expecting.

It's much harder to get time to work on it at the shop, vs. home. I'm trying to get the last few panel junctions opened up so I can finish blasting and get it back home where I can pop in and out on it. Minor spot blasting can be done at home on the areas I didn't get this go round. Still shooting for having her home by this weekend.

Im loving the fact that people are willing to take on projects like this to bring back to life, you are a hero to many people for your work, thank you, and what a great car, ill be watching this thread very much

Mine is worse than I thought it was going to be but I don't know about taking on a project like this. I envy those who are willing to do so to save another 68. Keep it up man!

Wow, heck of a project, it will be great looking if you keep up the good work!!!

So October is nearly gone, and she looks about the same. I lost the engine in my '67 at Silver State to a .020" pinhole in #3 cylinder wall and spent all my discretionary fundage getting it back together better than ever. It was finally ready to go in September so I was going to put it away and pull the '68 in to get worked on, but I lost my Job about the 1st of October and I've been working on other peoples cars to keep some money flowing until I find another job. I have absolutely NOT given up on it, if anything my resolve is stronger now, I just need to get my feet back on solid ground before I start playing again.

You guys keep me inspired!

Hi, nice project and nice pictures, I will use them to locate some holes etc on my car that is missing since I replaced some metal.
To bad to hear that you lost your work, I really don´t know what is going on in the US but you do have some serious problems.
Keep up the good work and I hope you soon get a new job!

So October is nearly gone, and she looks about the same. I lost the engine in my '67 at Silver State to a .020" pinhole in #3 cylinder wall and spent all my discretionary fundage getting it back together better than ever. It was finally ready to go in September so I was going to put it away and pull the '68 in to get worked on, but I lost my Job about the 1st of October and I've been working on other peoples cars to keep some money flowing until I find another job. I have absolutely NOT given up on it, if anything my resolve is stronger now, I just need to get my feet back on solid ground before I start playing again.

You guys keep me inspired!

Good times are coming, were mopar guys we don't let thats S%$# get us down, right!:naka: keep up the attitude and the workwill come back:icon_axe:best wishes!

Hey 67, with today's economy, the thing that is constant, and will be consistent is that in today's era of downsizing, corporate bottom line being profit, the bottom line (workers) are expendable. So, with this, the real growth sectors today are small business; like 1 or 2 people forming a consultation firm, or, a one-man show -- perhaps you could start up a 'Media Blasting Business' and become the expert in your field and in your area? I've done this, and never intended it to be anything more than a part time venture that could give me some $$ to supplement my Army retirement, but, it's grown and I now do more metal replacement/surgery than Blasting! Both skill sets go hand in hand, and I've started to capitalize on them, and it's working! I have work scheduled till late January, which is good for me, sad thing is I don't have enough time in the day to do all I need to do, or want to do! I did have a bloke working for me, I trained him how to blast, but he just could not master it after 3 months, and he ended up costing me more money than I was making; like my air compressor running too much b/c he (worker) didn't or couldn't appreciate a little thing like electricity costs money; the 3 months I had him my elec bill tripled b/c he just let it run and run...Now, I need a clone! Hang in there, and glad to see the progress is ongoing!

Despite the fact that I didn't get to finish blasting it before the weather went south and combined with the fact I don't work there anymore, I brought her back home. I can be doing a lot with the front end since it was blasted and primed. I'l begin installing the pieces I have acquired and spot blasting whatever will be enclosed that didn't get addressed yet. I have a good job prospect in the works, I've gone through 2 interviews and they really seemed to like me. If that works out the project will be back on the fast track. What little extra funds I do have I've been throwing at the credit card to get rid of it. It was no big deal when money was flowing, but when the tap stops, the interest is suddenly more important and a real drain.

I have plenty of labor to do in the mean time. I'd post pics but nothing has changed, just location.

I would like to ask a big favor, and yet I am thinking this may help more than me. When you do the door corners, can you do a detailed version of what you are doing? I have a pair of doors with the corners rotted out and I am planning on replacing the rust,,, BUT would like to see your take on how I should do that so that when I am done it does not look like a total POS.

Thanks

I will... I may skin it and repair the frame rather than fully reconstruct, not sure yet.

I am starting at the front and working my way back. Today I cut out some rust i at the inner fender to core support junction, up where the highest, front fender bolt hole is. I'm doing the least visible ones first to get the learning curve out of the way. So far so good, but it looks like I'll be replacing more of the passenger front frame rail than I had originally hoped. All good, I already have the complete rail from a donor car, I just will be using more of it. I'll add pictures when I get the kids to bed.

As promised, pics. This, although tiny, is officially the first metal to go BACK ON.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/Coresupportrust.jpg
http://img.photobucket.com/albums/v227/67Charger/68%20Charger/Coresupportrustrepair.jpg

Hey '67....you're doing a great job, keep up the good work! I know what it's like to be out of work...it happens. I just got a call and am going back to work after and extended "time off"...keep the faith, with your skills I'm sure it'll happen soon...all the best to you man!

WOW....absolutely amazing. you are a true talent. i wish i had body work skills, but i just dont have the patience but im glad you do.

"we can bring it back to life....we have the technology"

keep it goin...lookin better all the time!

Progress, finally. I have a full cowl as a donor so I separated the top from the bottom and I'll be patching in the bad area around the passenger side vent hole and then putting the donor upper on. I also went and bought a 1/2 pint of the Y-1 Top Banana Yellow that I am planning on painting the car so I can spray it under the cowl vents before reassembly. The original yellow was the bland creme looking one that I just didn't like as much. This way it stays close to original, but with more pep.

It feels great to actually be cutting and more importantly, REPLACING metal.


http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_8896.jpg
http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_8902.jpg
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Nice work, keep the pictures coming!!

It feels great to actually be cutting and more importantly, REPLACING metal

:popcorn:great thread...Love the surgery work....

What a great feeling putting new metal on, can't beat it. Good Job!

That front was blasted? Better get the entire thing re-blasted mate!

Yes, it was, as seen in the pictures a few pages back. Unfortunately it had to live outside for about 8 months. It really showed where I didn't lay the primer well enough. Regardless, it needs a full blasting anyway, so I am doing my structural patching in the mean time and spot blasting behind anything that will become enclosed before the full blast.

its really interesting to watch this surgery.....I don't think ive ever seen such an undertaking. I know i will now be removing my cowl after seeing the mess that was inside....maybe even setting up a removable plate to get to these areas once in a while....It is horrible to see cars in even better condition than this go to the scrap yard or be trashed in movies....But it is really cool to see a step by step......because essentially...it all is spot welded shaped metal and can be shaped and spot welded again...time and patience....a hammer mark here ....a grind mark there....slicing off 1 part of the elephant at a time....I really like this thread....lay the epoxy on well...its waterproof unlike other primers and will protect all that blasted metal....i will be following this from now on....truly an inspiration :icon_smile:

I got the first and biggest cowl patch fitted and tacked in. The back side is completely blasted and clean, the top side will get it with the rest of the car. I am WAY tempted to just knock off that ring and plate over it. Do the aftermarket AC systems use that hole? I'll never likely put a factory system back in it. I'm already planning on smoothing the firewall.

http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_9063.jpg

Moving forward...

The cowl patch is in and partially finish welded. I have some more welding to do but I need to add a small filler strip for the gap. The rest of it has blended nicely. The patch for the base of the A-pillar has been fitted, but I don't want to put it on until I figure out what to do for seam sealer. I need to buy the drip rails, but until then I'll patch the hole on the hinge post that will be covered by the forward most section of the new rail. I did ditch the rings since the aftermarket A/C's do not pull from there, so those will be patched and smoothed. The lower hinge post and side panel patch are getting close. I still have a little gap and some grinding to do on the side panel repair before I put on the new piece of hinge post. The d/s A-pillar and hinge post will be next up once this area is done.

The upper core support to inner fender joints have the outside patches installed with a little finish grinding to do before the inner patches get installed.

Since I have a good one in hand, I will be replacing the right frame rail to just behind the shock tower. I want to get ALL the cancer out of there. Aside from the small repairs on the inside of the d/s inner fender from battery damage, that will complete the front end. I'm debating doing the XV lower core support and inner fender/shick tower stiffening mods.

On Saturday I'm taking a drive a few hours each way to pick up a set of front fenders and a hood from a member on another certain charger board.


http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_9187.jpg
http://img.photobucket.com/albums/v227/67Charger/68%20Charger/IMG_9188.jpg
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