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The Willomet Charger
https://lh3.googleusercontent.com/7Z...=w1024-h682-no
Before we dig into the build, there's a long track that brought us to this point. From the beginning (excuse the large photos for the first page)... I picked up this 70 R/T nearly four years ago. Since then, I've built out the shop in preparation for this build and some major modifications to the shop truck, a squarebody suburban. That Duramax intercooler hanging in the background has a new home... https://uploads.tapatalk-cdn.com/201...a1fccae67c.jpg It's fairly complete - interior, trim, mouldings, lights, glass, suspension, drivetrain - really a rolling shell with no engine or transmission; perfect for my purposes. https://uploads.tapatalk-cdn.com/201...9d12197eb0.jpg It arrived at the shop filled with three things: lots of parts, copious amounts of rat scat, and a rattlesnake that had taken up residence in the truck. No doubt it wanted to be close to a reliable meal. The snake didn't wait long to move out, and truthfully I only ever knew he was there from the shed skins in the corner of the shop and the trunk. I try not to hate things in nature, but snakes are different. The interior was a biohazard, and I ordered the 3M mask and glove setup and got to cleaning the emptied car. I filled my shop vac several times and finished with a thorough rinse of the floor and inner door panels. It was funky. https://uploads.tapatalk-cdn.com/201...62f3a37217.jpg Having never disassembled a Mopar, I started cataloging and bagging and tagging the screws, clips, brackets with detailed notes as to how they went together and where. The reprint service manual was a useful guide. I should also say that every project - garage, house, car - is a chance to work with friends and family. https://uploads.tapatalk-cdn.com/201...4be8fefe02.jpg Disassembly would move along nicely from this elevated height: https://uploads.tapatalk-cdn.com/201...67cba281d7.jpg The objective is to build a car that will drive across the country and perform competitively against whatever monochromatic German machine it might encounter, as well as more recent iterations of American pony cars. We'll keep the solid rear axle, and make upgrades to the unibody so our chassis is rigid and predictable. After visits to Rad Rides, The Roadster Shop, and Gap Racing, I'm set on building a new front suspension and losing the torsion bars. The hope is to deliver power to ground rather than just evaporating the rear tires, which will have the largest contact patch we can reasonably fit in the wells with a mini tub. Big brakes, precise steering, a well sorted suspension, around 600hp, an overdrive, and a target dry weight of less than 4000 lbs are all part of the plan. Maybe I'm aiming high. Performance and long range comfort are the priorities, and in that order. It will be built by hand, and after stripping part of the rear quarter, it looks like I'll be placing at least one order with AMD for some new sheetmetal. https://uploads.tapatalk-cdn.com/201...06122cc7eb.jpg I guess the previous owner thought 1/4" of body filler could hide all the past sins. Next up: lots of sanding. David |
I never cease to be amazed at how many botched sheet metal repairs there are out there.
Oh well, looks like you're not going to be hurt too bad on this. Looks forward to hearing more about your plans on this one. |
It's a solid car - good rails, unibody is level and square, etc. I feel like I got lucky.
David |
Welcome David. Sounds like it's going to be a sweet project.
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The next several posts are all disassembly and discovery. Mainly, that this car was neglected and someone prescribed it way too much body filler. I spent a good bit of time pulling the last of the underhood hardware, and took apart the driver door trim, and can now add at least a passenger rear quarter repair panel or skin to the AMD shopping list. https://uploads.tapatalk-cdn.com/201...de0f2f2703.jpg https://uploads.tapatalk-cdn.com/201...929372e5f7.jpg https://uploads.tapatalk-cdn.com/201...e783bd6e6d.jpg https://uploads.tapatalk-cdn.com/201...1596d5d446.jpg Quick shot at what happens when you stitch too quickly over rust, and try to cover it up. https://uploads.tapatalk-cdn.com/201...d16de33635.jpg Both rear quarters are still leaded smooth to the roof skin. https://uploads.tapatalk-cdn.com/201...e95250347d.jpg Next: still, more sanding. David |
I've got a 70 in the garage for a future project. I'll be watching this transform. GL
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David, can you explain the how you came up with the name of "Willomet Charger?"
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Onward.
Sanded the majority of the passenger quarter and door, leaving behind only the non-bodyfillered sections. https://uploads.tapatalk-cdn.com/201...4866a356c9.jpg Also pulled the trunk lid and rear bumper and found more hack-job body work. The PO must have blasted or stitch welded without pausing, because there's a serious warp in the rear deck filler panel. https://uploads.tapatalk-cdn.com/201...7ffa9a01b4.jpg The 3/4" bondo sculpture artistry on the rear valence corners was impressive. Blue ribbon. https://uploads.tapatalk-cdn.com/201...20e1a1e860.jpg The spares for the truck happened to be out. https://uploads.tapatalk-cdn.com/201...afae2f504c.jpg Pulled the trunk torsion bars, driver door and quarter glass, and a lot of miscellaneous bits as I did my once-over to make sure everything is removed in advance if media blast. I did take a minute to organize; can't think straight if parts and tools are strewn about. Glass is packed and window mechanisms are carefully labeled and diagramed so I can put this back together: https://uploads.tapatalk-cdn.com/201...363972e09d.jpg It doesn't look like much, but the door and trunk lid represent about 5 hours of continuous sanding with the 3M strip discs and 80 grit on the DA. For the hood, it's the first time the steel has seen light in 45 years: https://uploads.tapatalk-cdn.com/201...b7c565942d.jpg I've seen this damage on other Charger hoods before: https://uploads.tapatalk-cdn.com/201...99c6126ebc.jpg Trunk isn't too bad with the same hack rust repair; it will be patched: https://uploads.tapatalk-cdn.com/201...caf968e53f.jpg Handy at the end of the day, the integrated b-body beer holder: https://uploads.tapatalk-cdn.com/201...b667cf73e2.jpg David |
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David |
David,
Great start on the Charger and I also enjoyed the write-up about the Suburban! One suggestion: cut down the size of the pictures here. You may have a giant monitor at home, but on a smaller monitor it is a little annoying having to scroll sideways. A good size is around 1200 pixels across for embedded pictures. Just a suggestion :-) Andrew |
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David |
The march toward media blast continues.
https://uploads.tapatalk-cdn.com/201...d7f01003ca.jpg Doors removed to save weight and improve my 60ft times. https://uploads.tapatalk-cdn.com/201...ec06dd1ffc.jpg 3M strip discs make a lot of dust, so I worked outside. Cowl, doors, and half the roof were all bare metal. Also pulled the last remaining brackets and hardware. https://uploads.tapatalk-cdn.com/201...db9313b665.jpg In the disassembly, I found the frame rails and crossmembers were filled with a fine sandy dirt. No kidding, there was a full dustpan of junk that rattled out as I rolled the car. All hail compressed air: https://uploads.tapatalk-cdn.com/201...815fe42281.jpg Finished roof https://uploads.tapatalk-cdn.com/201...2a577b4148.jpg Fenders done: https://uploads.tapatalk-cdn.com/201...394d213a73.jpg https://uploads.tapatalk-cdn.com/201...f08771fbff.jpg Lots more prep still to go. David |
Looks like a fun project.
I feel your pain on the previous owners repair attempts. I wonder if the same guy owned or worked on my 1961 Impala. :hairpullout: At least we both know how to fix these things. |
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You're right. I'm glad the car is mine, and I can take my time to make it right. David |
...and about those quarters.
Lots of old rust and rot and rat scat. My rational was, "why have them blast and prime panels I've already planned to remove?" The passenger side revealed a scabbed on patch using lots of adhesive. The inner structure appeared solid. https://uploads.tapatalk-cdn.com/201...385bccf33a.jpg https://uploads.tapatalk-cdn.com/201...4dce6d9f5f.jpg The driver side was much less dramatic. Prying the panels off the rockers confirmed they're fairly intact, if a bit corroded. https://uploads.tapatalk-cdn.com/201...c2850ec84b.jpg https://uploads.tapatalk-cdn.com/201...d46316bf90.jpg The inner sail panels have a lot of that resin. I assume the PO used it as a backing to mound up body filler on the outside: https://uploads.tapatalk-cdn.com/201...8a9c871e0e.jpg Once ready, we loaded her up on the trailer, and I took it to North Texas Customs. https://uploads.tapatalk-cdn.com/201...4fe3af2c5f.jpg https://uploads.tapatalk-cdn.com/201...b8cb079183.jpg I also took the fenders and doors, but I still have some work to do on the hood and deck lid, and they can be handled individually. They blast with a 40/80 grit garnet, and scrape off what that doesn't get - underbody coating, resin, etc. To avoid stress relieving and warping, only one side of a panel is blasted - they treat and sand the underside of the roof chemically and/or mechanically before priming. Turns out, this process is what the shop is best known for, and they have a good reputation from members on a few forums, the HAMB in particular. Big step for the car. David |
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Continuing work up front, I started patching some of the through-rust on the rails. The rails are all 14ga, so patching is a lot like sheetmetal repair.
Marked up rail highlighting damage: https://uploads.tapatalk-cdn.com/201...328d0e9741.jpg The rail under the bump stop brackets had spotty pitting; more pin holes to repair: https://uploads.tapatalk-cdn.com/201...4b9e2f0b38.jpg https://uploads.tapatalk-cdn.com/201...0687e4c0d0.jpg Also noticed the inner frame braces were deeply pitted, so lots of evidence that water collected in this area and never made it to the drain holes slightly farther back. Drilled the rust packed spot welds and cut out the neighboring pitting: https://uploads.tapatalk-cdn.com/201...40b9bfdae5.jpg https://uploads.tapatalk-cdn.com/201...2324a86ac4.jpg Fit the patch: https://uploads.tapatalk-cdn.com/201...5aa38258f4.jpg https://uploads.tapatalk-cdn.com/201...b0929593f6.jpg Ready for bump stops. https://uploads.tapatalk-cdn.com/201...82be0a166b.jpg Wrapping up some repairs on the inner part of the rail - pitting, spot welds, and porosity: https://uploads.tapatalk-cdn.com/201...de88d63e4d.jpg David |
repairs
Glad to see you doing a great job :military:
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David |
Taking a closer look at the UCA brackets, it looks like there are some cracks in those welds, too. I'm prototyping on the driver rail, and will duplicate on the other side.
Decided for a change of pace, and started on the battery tray repair/modification. Since the battery will sit in the passenger rear of the trunk, I figured I would reclaim these few cubic inches for the engine bay: https://uploads.tapatalk-cdn.com/201...2431290515.jpg https://uploads.tapatalk-cdn.com/201...0db8fb089b.jpg https://uploads.tapatalk-cdn.com/201...4f0aa11572.jpg David |
Some upper control arm reinforcement detail.
Removed with some additional welds: https://uploads.tapatalk-cdn.com/201...fca2b80e1d.jpg https://uploads.tapatalk-cdn.com/201...063a613223.jpg Make the stamped shape just a bit more resistant to twist and deflection: https://uploads.tapatalk-cdn.com/201...2245f6e881.jpg https://uploads.tapatalk-cdn.com/201...b3d7fd8e22.jpg David |
Coming along nicely Dave. I'm loving it...
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New acquisition time - I went to the Pate Swap Meet, and walked out with a TR-6060 transmission. https://uploads.tapatalk-cdn.com/201...c7e9a66f03.jpg This was pulled from a 2011 Camaro, so the gear ratios are right for the Charger. I wasn't looking for a 6060 since the shifter is something additional to engineer (compared to the T56 magnum), but this was too good of a deal to pass up. David |
David,
Great progress and thank you for adjusting the image size! Give D&D a call. I believe they have a kit that will convert a Camaro Tr6060 to a T56 Magnum. The swap is not trivial (main shaft needs to be replaced) but it might be worth it to solve the shifter issue and more importantly the output flange issue. Andrew |
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If I can modify the stock shifter, then I can also use The Driveshaft Shop's TR6060 adapter 1350 flange and build a conventional shaft. Need to stab the engine and trans and see where everything sits. David |
With all the planned chassis updates, I started the process of bracing the body. Frame table is next.
https://uploads.tapatalk-cdn.com/201...e7e192f44a.jpg https://uploads.tapatalk-cdn.com/201...3b3b5d9b7e.jpg Floors are out. https://uploads.tapatalk-cdn.com/201...d6ade603f8.jpg https://uploads.tapatalk-cdn.com/201...46c203f33b.jpg David |
With all the planned chassis reinforcement, I went ahead and built and mounted the car to a frame table.
1/2" adjusters: https://uploads.tapatalk-cdn.com/201...2fc4442b75.jpg Built it lower than most setups so engine/trans mounting doesn't max out the cherry picker: https://uploads.tapatalk-cdn.com/201...29f323131e.jpg Doubled 4" and heavily trussed: https://uploads.tapatalk-cdn.com/201...7ec9267b7c.jpg Love this little magnetic gauge from trick tools. Car is mounted and leveled: https://uploads.tapatalk-cdn.com/201...8063d5877a.jpg https://uploads.tapatalk-cdn.com/201...252d2c7b7f.jpg Next - open up the rockers, and prep for bigger inner boxes. David |
Fantastic work, gonna keep my eyes on this one for sure.
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With the car locked to the table, repairing and fortifying the rockers is the first priority. There are a few dents to pull and patches requires.
https://uploads.tapatalk-cdn.com/201...0df8050d95.jpg https://uploads.tapatalk-cdn.com/201...e777757566.jpg https://uploads.tapatalk-cdn.com/201...40df1eca29.jpg https://uploads.tapatalk-cdn.com/201...d30f085bf1.jpg Someone really jacked up the pinch on this car. They're deformed on both sides. Straighten rocker and pull the dent. https://uploads.tapatalk-cdn.com/201...55564467d9.jpg https://uploads.tapatalk-cdn.com/201...2db728cdbd.jpg https://uploads.tapatalk-cdn.com/201...6b8a2e24d5.jpg https://uploads.tapatalk-cdn.com/201...0ca38b7e49.jpg Got to get the foundation right so the rest will be square and strong. David |
Very excited to see this build! ...and yeah it looks level ;)
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David |
We're going with the Magnum Force front end. Their transformer K member is a very nice piece of gear. Took a break from working on the rockers and got this installed.
https://uploads.tapatalk-cdn.com/201...eb0c14b7f9.jpg https://uploads.tapatalk-cdn.com/201...5fb578ad80.jpg Just need to finish out the motor mounts: https://uploads.tapatalk-cdn.com/201...77a32398a6.jpg Factory stops removed: https://uploads.tapatalk-cdn.com/201...931e23b58b.jpg Back to the rockers. David |
:y0!: Where did you get the 1/2 '' adjusters for the frame table ?
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Amazon had a good deal:
Level-It - 1-7/8" Diameter Level Mount with 1/2-13 Threaded Stem https://www.amazon.com/dp/B0029MRUKK..._YOfqzbT35YM8F Local stores only had 3/8 and smaller, which might have worked, but I didn't want to be weight limited to how much of the car I could assembled on the table. David |
After a summer of off-roading, hiking, and client projects, I have some time to work on the Charger again.
Rockers are open and trimmed and ready for internal reinforcement. https://uploads.tapatalk-cdn.com/201...7adeaa18c9.jpg Rear section was chewed up pretty nicely my rust, and deformed at the pinch. https://uploads.tapatalk-cdn.com/201...5da01c2cd5.jpg Bent up a repair plate. https://uploads.tapatalk-cdn.com/201...c22c98b096.jpg Glad to be back working on it. David |
Very nice work:thumbsup: :thumbsup:
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It looks good, and that K member looks pretty stout.
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Some finishing details before welding. https://uploads.tapatalk-cdn.com/201...feba5d1d49.jpg https://uploads.tapatalk-cdn.com/201...b4614ec9f1.jpg For the mopar unibody nuts - this is the only taper, and there are no convoluted reliefs. Still plenty of room for the rear quarter to nest. https://uploads.tapatalk-cdn.com/201...d6e8551cc4.jpg .023 wire is loaded. Let’s go to work. David |
Welded. Blended.
https://uploads.tapatalk-cdn.com/201...fe755630bb.jpg Now to make a cap. https://uploads.tapatalk-cdn.com/201...1f91306a29.jpg David |
Large day with family. This is about all I could manage to get done with the hour I had early this morning.
https://uploads.tapatalk-cdn.com/201...f0a23e2270.jpg David |
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