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The Elephant In The Room: unloading the load from a B-body.

The stock brake pedal lever weighed 3 Lbs without the rubber sole pad.
Here's the 6061 aluminum brake pedal lever and foot pad before paint. It weighed 1-3/4 Lbs without the rubber sole pad.

It saved 1-1/4 Lbs.


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Here's the special machined 6AL4V titanium brake pedal swing bolt and nut assembly complete with aluminum lock washer. It all weighed 1.70 ounces compared to the stock one that weighed 3.25 ounces. It saved 1.55 ounces. All of this unseen. Now you see it because you never saw it before.

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and the tricks just keep on coming i love it
Ha, the bag of tricks is endless.
Here's a little simple dimple detail upfront at region #1 by the radiator support. Still haven't installed it since life gets busy sometimes.
Perhaps I'm just wishfully thinking of fetching one of those A-990 thin gauge radiator supports.

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Starting with Region #2 at its very border with the firewall, the factory door hinges, at least for the early '64-'65 B cars, weigh 11 Lbs without the fasteners. Unless a rare pair of the original '64-'65 Hemi package aluminum hinges happen to be burning a hole on your shelves, there isn't much of anything out there that is lighter.

Believe it or not, even more rarer are the reproduction aluminum hinges here that are carbon copies of the Hemi package types since less than a hundred pairs were supposedly casted and assembled. The pair weigh a whopping 4 Lbs.
That being said, some guys here have painstakingly drilled factory hinges to almost half their weight and combined with lightweight fasteners can contribute to a respectable weight loss.
This is also applicable to most hinges on other models and years, but should only be considered for swinging doors that are somewhat lightweight themselves by way of fiberglass, aluminum, gutting or chemically milled.

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Fiberglass doors seem to be the way to go easiest when removing weight right at front and center of region #2.
Starting with Region #2 at its very border with the firewall, the factory door hinges, at least for the early '64-'65 B cars, weigh 11 Lbs without the fasteners. Unless a rare pair of the original '64-'65 Hemi package aluminum hinges happen to be burning a hole on your shelves, there isn't much of anything out there that is lighter.

Believe it or not, even more rarer are the reproduction aluminum hinges here that are carbon copies of the Hemi package types since less than a hundred pairs were supposedly casted and assembled. The pair weigh a whopping 4 Lbs.
That being said, some guys here have painstakingly drilled factory hinges to almost half their weight and combined with lightweight fasteners can contribute to a respectable weight loss.
This is also applicable to most hinges on other models and years, but should only be considered for swinging doors that are somewhat lightweight themselves by way of fiberglass, aluminum, gutting or chemically milled.

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Here are Titanium T-6AL4V fasteners for the door hinges with the guide noses machined in for ease of thread catch.

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Fiberglass doors seem to be the easiest way to go when removing weight right at front and center of region #2, but fiberglass doors are usually a mess right from the mold and need a lot of work for proper fit and function. If the car is of a hardtop variety with no upper post bridge to hold in place a glass pane, lots of frame work has to be had to accommodate that glass usually with ugly or revealing results. I'd like to think that some folks on here are trying to be low key with their respective programs. Fiberglass is also prone to cracking or wearing out fast if careful handling during use aren't considered.
I've never weighed them, but they are light and only a couple of fiberglass companies (open for debate) are reputable molders and shippers. I would suspect that glass doors are in the 8-12 Lbs range in naked form with no internals.

Steel doors for B-cars below 1970 whether they be post sedan or hardtop open air types aren't as heavy as many may think. They each weigh anywhere between 32-40 Lbs naked. The 1971 and later B cars are a different breed and as a result, had longer doors with some even having inner crash beams installed starting sometime in late '72 into '73, thus, they are heavier and bulkier. This is not to say that these cars can't be unloaded of their loads, but one just has to go through a more scrutinizing process to do so.

Removing all sound deadener or rust proofing material from the inner sides cuts weight down on any car, but it doesn't come without some serious elbow grease along with some nasty cuts from those inner door panels.
Surgically and strategically cutting out unnecessary inner door panel material without hampering the function of the windows can toss a little over a pound out the widow itself, but is it worth it? I thought so. This was many years back following on the concept that every ounce counts.
On the other hand, cutting out the main bulk of that inner panel (like DVW has on his '64) can remove a few pounds at least and even more with the removal of the rooster crank system altogether. Only thing is that if you want the window to function like the factory intended it to, you have to fabricate a lightweight system like DVW's and keeping in mind that this only works best on post/sedan doors.

That being said, stock doors that get a chemical milling make the best sense while remembering that these doors are actually starting to get scarce.

I'm not trying to showboat here, but as far as '64-'65 B cars are concerned, the next best option would be the rare '65 A-990 thin steel gauge doors. Problem is: Try and find a pair.
If you really get luck on your side, the '64 A-865 Race Hemi aluminum doors are the next best lightweight option that comes close in fiberglass weight territory. Problem is: You won't find a pair without them being tethered to an entire aluminum front end.
These are post sedan types and are exact duplicates of their steel counterparts. They were only offered on the Race Hemi package cars and not on the Max Wedge cars which by early '64 were already being phased out in favor of the incoming elephants.
For comparison sake, a factory steel door in naked form is more or less 39-1/2 Lbs. An aluminum door in naked form is exactly 15-1/2 lbs. A true 48 pound difference when you factor in a pair.

Back in '90-'91, I dropped the ball on a pair of NOS aluminum jammies in their Chrysler boxes and never saw another set that were anywhere near decent used-uncut-unmolested condition until 22 years later when these pups came along. As you can see, there were a lot of small pockmark dents on them, probably from curiosity as to their alloy skins. Other than that, they were mint and my friend "The Palm Reader" excellently restored them to their smooth surfaces with little to no body hammering and putty.
This single aluminum door comes in at a poultry 15-1/2 Lbs in naked form, but wait!.............there's more to this than meets the naked eye.

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Lightweight door or not, here is where the devil is truly in the details.
Starting from the very top.
The little lock knobs are usually metal and can weigh a few ounces, but the plastic types are so light, that it doesn't even register on the scale.

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When I got replica Super Stock door panels made, I had them leave out the hole for the door locks as I had removed the button and rod. Some people notice that they are missing, but most don't. I just checked my notes and I can't find where I had weighed the button and rod. I will have to find them and weigh they just for kicks.
 
When I got replica Super Stock door panels made, I had them leave out the hole for the door locks as I had removed the button and rod. Some people notice that they are missing, but most don't. I just checked my notes and I can't find where I had weighed the button and rod. I will have to find them and weigh they just for kicks.
All these small and seemingly irrelevant parts add up. Don't have the weight figures in front of me, but it was well worth it in the scheme of things.

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When Legendary was planning to close the door on their limited run of Super Stock interior door panels, I didn't fess up or flinch and probably received the last set made in black. The sales man told me that mine were the last ones in stock and they weren't planning another run.
I know that the A-865's and A-990's had specific interior colors that did not include black, but I wanted black for my specific Black on Black on Black car.
As one can see, the interior material wasn't wrapped up and over the upper door trim panels which are usually covered by the material because I made those out of aluminum. They are wafer thin and weigh almost nothing. The hardest part was making the exit hole for the door knob rods and installing the small trim ring with out leaving an impression.
What you see here is a seemingly stock upper trim panel innocently painted black, but stock it ain't. Again, I don't have the weight figures in front of me, but I will post them as soon as I get a chance.

If using factory window crank handles, the use of rear or wing window cranks saves perhaps a half pound between both doors because they are smaller as seen here. By the way, all fasteners holding everything underneath such as the window crank mechanism and related brackets are T-2024 aluminum.

I will post up something special concerning the main interior door handle seen here.

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Here's a gem that I've experimented with. Yeah, its crazy and its aluminum, but crazy gets things done.
An original steel door handle weighs 5.35 ounces at just under a 1/2 pound.
This aluminum specimen made through a 3D printer weighs 2.20 ounces. The cad file for the printer coordinates had to be formulated by a gentleman in Detroit that is savvy with this stuff.
After some sanding and buffing cycles to achieve a chrome luster this coming Winter, it should fool any eye as a factory unit.

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To not divert away from the dash, note that the factory AM radio such as the one that once resided here was a whopping 6-1/2 Lbs alone so it had to go off the air. This wasn't even taking into account the speaker up front just under the dash. For some reason, I never got a chance to weigh the speaker, but muscle memory bets it was somewhere near 4 Lbs.

The dashboard heater controls are gone and so is the heater blower and housing assembly underneath the dash. Who needs heat when header pipes just underneath provide it. It all shaved 30 Lbs.

In place of what would be an obvious radio delete plate is a Autometer Ultra-Lite lightweight series 5" tach installed in its own 20 degree tilted aluminum casing. Excuse the shoddy silicone bead hiding the spot welds underneath.

In place of the heater control panel is the Ultra lite water temp gauge. A plus to this was that the cast metal material directly in back had to be milled/filed off to make way for the gauge, so a few ounces were given the eviction notice.

In place of the heater blower itself is nothing other than open air/desert which lends itself to a good place for an MSD ignition box or other control modules. It also allows for easy access to gauge plumbing and cluster wiring which amounted to a full 1/2 pound of decommissioned wire removed.

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My 66 came with factory AC....how many /6 cars had it??! Kinda wish it was still in the car now since it's not going to be an all out race car anymore.
Some of the under dash copper spaghetti I was talking about. You'd be surprised what unnecessary wiring weighs.

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Oh man, I know how much wiring weighs!
While in the realm of weight loss, but not really something ‘stealth’, I drilled/shaved the lard from the hinges on my 65 Belvedere. I didn’t do too bad in the process. An aluminum hinge set of 4 (with aluminum fasteners) weighs in at 4.6 pounds (estimated with info from Kramer). The stock steel hinges from my car weighted in at 12.4 pounds for the set of 4 (with steel bolts). My lightened set comes in at 5.9 pounds for the set of 4 (with titanium bolts). So, the end result is a 6.5 pound weight savings over the OE hinges, but still comes in at 1.3 pounds heavier than the ultimate aluminum hinge set (but my wallet is $700 heavier in the process).
Like I said, not exactly stealthy, but it works for me.
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Did that to my hinges too but more so! Also worked on the stock fasteners. I'm on a shoe string budget.....and hate it but know how to not spend money.
I tried drilling the upper hinge on the body side of my 64. Couldn't find a drill bit that would even touch it. Carbide just made it shiny.
Doug
That's wild.....what does a file do to them? The file 'test' is usually a good indication of hardness.
The door shells themselves are not so heavy, considering their size but a little reaming or hole sawing on the interiors doesn’t hurt. The doors on an E body is epically heavy in contrast. The wing window track assembly and the rooster window crank system starts to get heavy.
Oh geez, E body doors are horrible! Pulled out the side impact protection rails on a 70 A66 car and was surprised how heave they were. I weighed them back in the mid 70's when I did that and iirc, they were over 20 lbs each
I drilled holes in my brake pedal lever taking it from 3.2 pounds down to 2.2 pounds.
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Been there too lol. Have you used that one and stood on it hard? Did one on a 70 Challenger but did rectangles instead of holes. Several years down the road this guy offered me stooopid money for the body....his son totaled out his RT and he was looking for a good body to move the numbers over to. Told him lots of numbers to move but he didn't bat an eye. The body was solid but had lots of 'whiskey' dents in it which I had already finished fixing. Hate body work and kept thinking no no no but he kept upping the price until I finally said sold.
 
Now that this conversation has found itself deep in the interior, here's a repost of the interior trim panels after chemical milling. The rear quarter window pieces are the heaviest out of the bunch of course.
There are two B-post panels that are not in this picture because they were easily made out of aluminum, but nevertheless were weighed with the whole set.
6-1/2 Lbs in stock form.
After the bath they all weighed 3-3/4 Lbs, so 2-3/4 Lbs were removed.

The two upper door trim panels are also not included in this picture because they were also made of aluminum.
The two panels in stock form weighed 3 Lbs.
The aluminum types weighed 1-1/8 Lbs for the pair. Roughly 1-3/4 Lbs was removed.

In Total 4-1/2 Lbs removed when all is said and done.

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@fullmetaljacket Deleting PM's.

If you started the message, hit the drop down button then click on leave. If someone else started the message, the leave button will show at the top of the message box. It's a pain now to delete multiple messages since the upgrade because they can't be deleted en masse anymore. Sorry it took me so long to get back to you with this.....
 
Let's not forget before going south of the border at the doors of certain unseen items.
Headliner insulator, cowl and kick panel insulator pads and metal coat hooks. 3 Lbs removed and never missed.

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I didn't have much in the way of firewall sound deadener and I forgot to weigh the stuff I took out of the interior panels. But, the dome light, bracket, wiring, coat hooks and roof insulation amounted to just over 2 pounds. I take it where I can get it.
 
I didn't have much in the way of firewall sound deadener and I forgot to weigh the stuff I took out of the interior panels. But, the dome light, bracket, wiring, coat hooks and roof insulation amounted to just over 2 pounds. I take it where I can get it.
I didn't have much in the way of firewall sound deadener and I forgot to weigh the stuff I took out of the interior panels. But, the dome light, bracket, wiring, coat hooks and roof insulation amounted to just over 2 pounds. I take it where I can get it.
The two interior door panels and the two rear interior quarter panels with armrests and hardware weighed 14-1/2 Lbs. Aluminum sheet panels in place of those weighed 5-1/2 Lbs.
Since then, I have installed the Legendary SS panels as seen above and put on a few pounds, but not as heavy as the original civilian factory panels. The upper door trim plates made out of aluminum helped keep the numbers in check.
I'll check my records and get back with the weight for the SS panels as they were right out of the box without the upper metal trim panel. I think they also call this part the sill panel of sail panel.
 
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I got my inside door panels from Gary Ball. At the time, I had to supply my own upper metal pieces from my original panels. I believe he has them available in fiberglass now. I am tempted to get another set for the lighter weight.
 
I got my inside door panels from Gary Ball. At the time, I had to supply my own upper metal pieces from my original panels. I believe he has them available in fiberglass now. I am tempted to get another set for the lighter weight.
Fiberglass, now that's cool. Great alternative to all the work I went through to make 'em out of the lighter alloy, but then again, it wouldn't go with the theme of the car which is to create or replace everything imaginable with lighter metals. Hence: FullMetalJacket.

I've heard that those original metal uppers are now hard to get at all or at least in decent shape.

My A-100 seats are from Gary Ball, but I bought them only if he would bring them to the Nationals in person because I heard that many people were waiting for long periods of time after ordering them over the phone. Don't get me wrong, cool guy and an even cooler product, but I was on a NOW mission back then.
The Legendary panels were nicely done and unfortunately they discontinued them shortly after the run.

Next, I'll be showing everything about the seats and everything around them. Over a 100 Lbs removed. Stay tuned.
 
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