Project SCUD, '69 Dart
 

So I've been on lat-g for a while but haven't posted my build here because it's on another site. Lately I've seen a few builds on both so I figure what the heck, I'll throw it up.

The back story on my project is I've had the Dart for over 10 years, but it hasn't felt the road in around 7. When I finally began moving on it, the project started out innocent and simple enough. Plans were originally all of the Reilly Motorsports goodies, front and rear, some Mustang FR500's, 5.7 Hemi, A518, 8 3/4, Viper blue paint, buckets, etc, but nothing super crazy or out of the ordinary. THEN, I discovered lat-g and p-t and started dreaming, alot. Then I found the must have wheels for my project:

http://i876.photobucket.com/albums/a...heels_Rims.jpg

After I found a set of these with tires for a ridiculous price, I had to have them and the project spun out of control. It went from a relatively simple, mostly bolt-on, panel replacement, resto-mod, that would be finished in a reasonable amount of time, to a full chassis, full-on Viper theme, IRS, custom almost everything, praying it sees the light of day under it's own power in my lifetime project. Unfortunately for me, I didn't know crap about welding, suspension, almost nothing. So I started researching and reading, alot. Truthfully, this was the best thing that could have happened for me because I have learned so much. It has cost me a lot in parts, and learnings, but that is the fun of the process. I am now at a pivotal point in the build and plan to take it off the chassis table later this year, and let it rest on the ground on it's own tires for the first time in I don't know how long. I have parts coming in for this build almost weekly. I have researched the best quality parts I can afford and that's what I'm using on the build. I will only do a build to this extent once, and I'm making the best of it.

I've been working on the car for 3-4 weeks a year for the last two years; I live in Switzerland and build in Grand Rapids, MI when I'm visiting at Christmas. It sucks, but I get a lot done and I've been blessed with some incredible help to get me there, and teach me some stuff along the way. My next trip back to work on the car will be this Christmas, then I hope for a couple weeks at my semester break in February/March 2012. I have some great stuff that is on order and will be ordered shortly and I'll be sure to post updates as it comes along.

The next few posts will mostly be pictures as I bring this thread to the projects current state.

One of the first things I did after buying wheels was have a rendering put together. I had one done by a guy on a Mopar forum, and eventually wanted to have it reworked. At the time of the rework I couldn't get in touch with the original artist so I connected with Shawn Mascoll via this site and this is what he put together.

http://i876.photobucket.com/albums/a...Tmp00001-1.jpg
So this is the blueprint. The car will be BMW Interlagos Blue Micah and Mercedes Benz Iridium Silver. Ride height is 5" to the chassis and will sit on a custom set of Ride Tech shockwaves.

Following are some pics from last Christmas, cutting the car to almost nothing and starting to mock-up the Viper suspension components and the 5.7 hemi/T-56 combo.
http://i876.photobucket.com/albums/a...7/IMG_2673.jpg

http://i876.photobucket.com/albums/a...7/IMG_2754.jpg

http://i876.photobucket.com/albums/a...7/IMG_2751.jpg

http://i876.photobucket.com/albums/a...7/IMG_2761.jpg

http://i876.photobucket.com/albums/a...7/IMG_2759.jpg

note the size of the Viper UCA's and the fact that I can not fit the Hemi between them.
http://i876.photobucket.com/albums/a...7/IMG_2756.jpg

test fit of the big jabroney (6'6") pilot.
http://i876.photobucket.com/albums/a...7/IMG_2797.jpg

I ordered shorter UCA's and while waiting for those I began cutting up the rockers since I was planning to move the chassis perimeter into the rockers.
http://i876.photobucket.com/albums/a...7/IMG_2798.jpg

New UCA's arrived and I started reworking the suspension. Little did I know, the suspension would go through 3 design revisions, only to be finalized last week!
http://i876.photobucket.com/albums/a...7/IMG_2802.jpg

So that was Christmas 2010, and this is how I left the car.
http://i876.photobucket.com/albums/a...7/IMG_2804.jpg

My next trip to the states was between school semesters and I had 3 weeks of playtime. My wife was not with me on this trip and I made no plans to visit with anybody, accept the nieces and nephews of course. This trip was all business. My goal was to have the car sitting on it's own wheels by the time I left. This meant building a full chassis, installing it, suspension, engine/trans, etc, all while overcoming a bajillion obstacles that I had no idea were coming. To alleviate the suspense, I didn't make my goal. I could have but I chose not to rush it and left the car on the table for the next trip; smartest decision ever!

So coming back it was time to build the chassis. I had spent almost a year of a few hours here, couple minutes there, designing it in google sketch-up (not exactly a great CAD program but it's free and you get what you pay for). So from that I started cutting 2x4 steel...
http://i876.photobucket.com/albums/a...7/IMG_2799.jpg

and welding rails...
http://i876.photobucket.com/albums/a...s77/file-2.jpg

and assembling a chassis...
http://i876.photobucket.com/albums/a...s77/file-4.jpg

the first iteration of my front rails failed as I forgot some basic 7th grade geometry about splitting angles between two tubes, it takes two 12* cuts to get 24*, not two 24*. So this is the chassis with more to come, and being taken away.
http://i876.photobucket.com/albums/a...s77/file-9.jpg

A sampling of some of the over-build parts for the suspension, spohn del-spere pivots joints and howe ball joints. 6 more Howe ball joints will be in route next month.
http://i876.photobucket.com/albums/a...s77/file-6.jpg

The beginnings of the back brace.
http://i876.photobucket.com/albums/a...77/file-11.jpg

beginnings of the rear suspension drop-out.
http://i876.photobucket.com/albums/a...77/file-13.jpg

And here is where I could have stopped since technically it's a roller.
http://i876.photobucket.com/albums/a...77/file-26.jpg

from there it was back to suspension mock-up (with the second iteration of front suspension geometry)
http://i876.photobucket.com/albums/a...77/file-29.jpg

brackets designed and laser cut by a buddy (all to be replaced this Christmas with the third and final, and amazing, iteration of the suspension geometry; with huge props going out to Bryce for a hand in making it right!)
http://i876.photobucket.com/albums/a...77/file-31.jpg

I then began working on incorporating bumper mounts (again, being reworked this Christmas)
http://i876.photobucket.com/albums/a...77/file-40.jpg

solidifying engine placement (Hemi soon to be replaced)
http://i876.photobucket.com/albums/a...77/file-46.jpg

rear suspension
http://i876.photobucket.com/albums/a...77/file-55.jpg

rear crossmember/bumper mount replacement (slight rework coming, nothing too major though)
http://i876.photobucket.com/albums/a...77/file-52.jpg

beginning initial mock-up of replacement core support
http://i876.photobucket.com/albums/a...77/file-57.jpg

decisions on what to do about headers (irrelevant at this point)
http://i876.photobucket.com/albums/a...77/file-58.jpg

and this is where I ended this past spring. I could have pulled it of the table with some shock mock-ups or even using the stock Viper shocks I have under the work bench, but I wisely chose not to.
http://i876.photobucket.com/albums/a...77/file-59.jpg

Since March, the suspension design has gone through it's final iteration and it's now an almost perfectly balanced (suspension wise anyway) design, front to rear. Again, a HUGE thanks to Bryce for taking my design, making it WAY better and getting it just right. Unfortunately this means I have to scrap the LCA's I built for some new ones, replace the UCA's with ones slightly longer, and build new brackets. I'm having Art Morrison bend up a new front cross member from 2x4 and am hoping to have them install the lugs for the LCA's and the steering rack, I should hear back on that in the next couple days. At the same time, I'm going to have them bend up new rear frame rails in a different design so I can have some extra room for a Rick's Tank under the trunk floor. Another reason for the new rails is I pumped WAY too much heat into these rear rails and warped the drivers rail so much that the rear tire has oodles of positive camber (painful lesson to learn). Rather than cutting, bending, rewelding, etc, I decide to replace it with a one piece rail, should work out awesome! I've been ordering a ton of parts throughout the year and have a lot more to go. These include:

Ride Tech Select Series Shockwaves, essentially a Viper kit but with a convoluted bag on the rear instead of rolling sleeve.
http://i876.photobucket.com/albums/a...77/file-75.jpg

fiberglass hood with a Viper hood skin grafted to it. this is not finished yet and the builder will be pulling a mold from it to resale once finished.
http://i876.photobucket.com/albums/a...77/file-66.jpg

http://i876.photobucket.com/albums/a...7/100_1644.jpg

I ordered a fiberglass decklid which I will be building a custom spoiler into and incorporating a Gen 3 Viper brake light, picked up some new US Body fenders for 1/2 off from a guy that decided to use steel instead. I ordered a ton of hardware and miscellaneous items for the build and for the rotisserie I'm building. A very cool and modern rear defrost setup from frost fighter. Some items for chassisworks, more panels from AMD will be on there way soon too. I ordered a Woodward Steering rack yesterday. The new UCA's (front and rear) will be bearing mounts from Joes Racing. Some header parts from Stainless Headers to build a set for the new motor, a bunch of new tools to make building easier, a Ford GT-40 lemans filler cap that will be recessed into either the top of the quarter panel or the middle of the deck lid filler panel. A TIG welder, cuz I figure if I'm building stainless headers, I should TIG them (another new skill to learn), and a bunch of other fun stuff.
I'll be sure to post pics of my new toys as they arrive, cuz that's all I really have to keep me going the next three months.

Come January, I'll be ordering an ididit column and my Rick's Tank probably in February.

That pretty much brings us up to date, with the exception of the engine. When I first saw the 5.7 Hemi I wanted one for my build. I got a great deal on one and was good to go. As the build evolved into the Viper inspired project it is now, I continued to ponder the significance of a V10. I was finally harassed into doing the V10 and got a good deal on one pulled from a 2000 RT/10. It's a Gen 2 which is only 450 hp, 490 ft/lbs, but with a few simple mods I'll easily 550-600 at the wheels. Now I just need to figure out how to maintain some semblance of leg room.

http://i876.photobucket.com/albums/a...77/file-77.jpg

that is a very cool project Will, thanks for posting.

I really enjoyed reading and viewing your progress. You are doing a great job! That V-10 is going to need an exceptional exhaust system. Do you have any ideas yet?

Not sure on exhaust yet. My height (6'6") has dictated some decisions on how the chassis went together, in order to maximize headroom, which will make routing exhaust difficult. My tunnel is 8" wide and the exhaust will have to run through there. I was originally planning to bring the outlets through the rocker in front of the rear tire. I'm thinking that idea is going by the wayside for now. I've been researching mufflers and I'm not sure what I'm going to so yet. The V10 has a unique sound and I can't just get an off the shelf Viper muffler because most of them (GTS excluded) were side exit exhaust with the muffler in the side sill. I wish I could demo mufflers...

Thanks Jody.

Yes, I follow you. I suspect you will be going through many iterations of exhaust before the final. Most V10's either sound good or bad, nothing between. The good ones do sound sweet though.
Again, keep up the beautiful work!

Very cool project!

Can you use oval tubing to get the clearance you need for the exhaust?

Really cool project Will. I've been following over at PT. Glad you decided to intro Scud over here! Keep going Sir...:thumbsup:

Very awesome Will. Great work. That Dart should be a killer build.

I can but it's not so much ground clearance that I'm dealing with. It's just a very narrow cavity that I have to run it through. I really wanted side exit exhaust through the rocker similar to the Viper but it looks to be too complex at this point. However, I will however pick up some 3" PVC this year and play with some mockup to see if I can make it work. Will be way simpler to run it out the back, but that's also not the vision. We'll see.

Thanks guys.

What an incredible build

Looking good man, what do you think about those spherical joints your using on control arms? Arey they only on the front suspension?

Great work Will !!

I've had several 69 darts over the years and always wanted to do something simular to your build. The original suspenion, tire width and brake selections just won't fit the body for any real PT type car effort. One 69 I had was a 440 mag - but without mods to the wheel wells I could never get any traction and it handled even worse...

For exhaust routing - maybe check out Bob Johnsons cuda project ? It turns 90 degrees at the front of the rear tires and exits out the side of the car. You might have some space for muffler selection. Just an idea.

Great design and I can't wait for more progress !!

Jim

Love the car man. Going to be killer when you get it all done. Keep the work coming! :thumbsup:

Beautiful build...

I cant believe how much you seem to get done in your little "bursts" of work when you get to work on the car.

I agree with Ned.

Will,do you even sleep in those couple of weeks :willy:

Have you thought about widening the tunnel to fit exhaust ?

I love the Del-Sphere's. I have a set that will be going on the rear LCA's as soon as I build them. Probably overkill for A-Arms but they are nice and ultra smooth.

Thanks Jim. I completely agree with you. I'll check out Bob's Cuda to see what idea's I can snake from it.

I don't get much sleep that's for sure. Was just telling my wife tonight that it will probably be less this year than last too. Already looking for tickets for a couple weeks from the end of February to Mid-March. If I can get my Rick's Tank by February (dependent on me and cash flow, not Rick), I may even be able to get it running...

The only problem with widening the tunnel is I lose much needed interior room. But I will consider it. I'm going to mock up some headers out of PVC and mock up exhaust routing in PVC as well. That will give me a chance to play with things before I make a final decision on the direction.

I got your PM too Stefan. I'll connect with you next week.

Thanks Ned. Doesn't pale when compared to yours but thank you.

Will,

Thanks for the props!

Needs to be given where it's due Bryce. Ordered my Woodward rack a couple nights ago, can't wait to see that thing finished; 22.18" on the money it will be.

What an awesome Project! Can not wait to see it when its done! Love the fact that your building the whole frame yourself! Keep up the good work! :thumbsup:

More parts for me! It's killing me not to be able to do anything with these!

Woodward Steering Rack & Pinion...
http://i876.photobucket.com/albums/a...77/file-79.jpg

Joe's Racing Bearing Mount Upper Control Arms that will be used in both the front and rear...
http://i876.photobucket.com/albums/a...77/file-78.jpg

RideTech 3 Gallon Tank... (and uber fat guard cat)
http://i876.photobucket.com/albums/a...77/file-81.jpg

I've also designed a bracket that will clamp around the air tank that will hold both the compressor and the valve block. All of it will be mounted under the car between the frame rails. Will work out AWESOME, and save some space in the trunk.
http://i876.photobucket.com/albums/a...rtankmount.jpg

how cool is that!!!!!!!!!!!!

just read thru this... quite the undertaking.....looks good Will

Thanks Gary. If I'm honest with myself, it's much more of an undertaking than someone with no skills "should" have considered getting into. It's been an awesome learning experience though.

The hood for my project is coming along nicely! I can't wait to see this thing finished. The next step is to have a mold pulled from it so it can be recast into one seamless piece, rather than the many pieces it has taken to get here. Should be done just in time for my return to the States and my mega-thrash.

http://i876.photobucket.com/albums/a...77/file-84.jpg

http://i876.photobucket.com/albums/a...77/file-83.jpg

http://i876.photobucket.com/albums/a...77/file-85.jpg

comepletely out of the box

Thanks a bunch.

looking good man

That hood is a work of art!!! :)

That hood looks great!

Recently pulled the trigger on some new uber coolness for my hot rod's electrical system, MiMod HP, a perfect complement for my ISIS. Includes twin 7" LCD displays for the dash that will be my gauges. We are designing those now and the initial images are pretty cool. Also includes a tablet PC that will be mounted in the center of the dash and will handle all the switching and electronics on the car. That means no buttons, knobs, switches, sliders, or anything else on the dash, just LCD gauges and a touch screen. In addition, the tablet will also handle air suspension operation, OBDII integration, WiFi, HD/AM/FM Radio, MP-3, CD/DVD, Back-up Camera, GPS, Vintage Air operation, eventually TPMS & Handsfree/Bluetooth phone capability, and almost anything else I desire at a later date. Oh so fun. I REALLY hope it works out to have someone do the bodywork for me while I'm gone next year so I can start on all this wiring coolness...

I'm back in about a week and a half and have oodles and oodles of boxes of parts to sift through. So much junk my photo-journalist can't keep up, then there is, of course, the super haus V10... First I have to get through a couple exams and a bunch of writing on my thesis so I don't have to think about IT while I'm working on the car, but it is real hard staying focused right now. Almost all the parts are in house or in route with a few more to order yet. Gonna be fun times in the shop.

10 days.............................................. ............