66 Charger drivetrain overhaul - time for some changes

[Don Frelier]

I made a new positive battery cable on Sunday and wirewheeled and coated the h-pipe this evening.
So much better now that the humidity dropped.
Rear axle is rebuilt that will need to be needle scaled and coated

 

[Don Frelier]

Exhaust and starter are installed. The rear axle is back from the rebuild.

 

[Don Frelier]

I bolted in the leaf spring hangars and attached the front of the springs.
Needle scaled ground and wirewheeled the rear axle.
It took a few hours.
Looks good painted, at least I think so.

And the left front tire is installed.
It may even stay on until I push it out to fire it up

 

[Don Frelier]

I asked my older son (the boxer)to help me carry the axle back inside the garage.
He said oh that's no problem just picked it up and carried it in like an armful of wood.

Got a few more things mounted, found I needed a longer throttle cable.
Didn't think of that problem.

 

[Don Frelier]

I have been working on the car but there were some interruptions and I simply didn't feel well for about a week.
The rear end is back in and bolted up just need to tie in the e-brake cable, bleed the brakes,tighten up the exhaust and install the driveshaft.
Then the rear wheels can be put back on after about 5 months stacked in the corner.

 

[HawkRod]

Getting there Don!

 

[Don Frelier]

I put in an 8 hour day today and David came and helped for a few hours.
I installed the driveshaft, touched up the rear axle paint, trans cooler lines, heater hoses, new throttle cable, intermediate shaft, plugs, distributor, wires and battery. (Which turns out is NG)
Tested the starter but had a leak in the return line to the fuel regulator. I was hungry and getting tired.
Got a new battery and I should have parts to fix the leak.
So tomorrow should be the day to fire it.

 

[66chargerpat]

Looking great

 

[Don Frelier]

We have IGNITION!
Both my boys helped me out.
The return line leak was repaired after a bit.
Stuck a new battery in it cleaned up the table and boxes of parts.
They pushed it out into the brilliant sunlight for the first time since the end of April.
Filled the radiator with water and we were ready to go.
We ended up running three times for about 7-8 minutes each.
The first time we shut it down because we smelled plastic burning, turned out it was the speedometer cable melting on the exhuast pipe.
I must have missed a clamp underneath when I was painting or after we installed the transmission.
We put a fan on it for about 15 minutes and refired it a second time.
After another 7 minutes or so we smelled plastic again and shut it down.
Turned out we couldn't find anything so decided it must have been residual from the first melt.
The third run it got up over 200 even with the box fan a fairly brisk wind and no hood.
I backed it into the garage under it's own power and it was very responsive just getting it over the apron it jumped when I touched the throttle.
Decided to spend the remainder of the afternoon sorting and putting tools/stuff I was done with in the truck to take home.
I'm uploading a video of the first start but it's kind of long. I'll see if I can cut it down.
If I were smarter I would have got a picture of the three of us in front of the car.
A missed opportunity.

 

[Don Frelier]

Cooling off after the first run

Back in the garage to plan from here.

 

[Don Frelier]

Here's the video coverage of the first run:

You want this young man on your pit crew.
He does a great job.

 

[Don Frelier]

First test drive today:
cleaned up and put away much of the parts last week.
Unfortunately the o ring I picked for the transmission fill tube is too small so that leaks. But that can be remedied.
Cleaned up the wiring a little and slapped a 3" air filter on it.
My son helped me lift off the hood and followed me in the truck for a quick 5 mile loop. We stopped and checked the trans fluid then he drove for another 6-7 miles.
Runs really well just trying to keep breaking everything in for now ran between 2,000-3,000 RPM.
The rear did make some alarming noises though when we turned? Seemed to get worse after we drove it a while. Hopefully the some figure 8s and let it sit overnight will correct it. I'll check with the rear end guy and see what he recommends.

 

[Nxcoupe]

First test drive today:
cleaned up and put away much of the parts last week.
Unfortunately the o ring I picked for the transmission fill tube is too small so that leaks. But that can be remedied.
Cleaned up the wiring a little and slapped a 3" air filter on it.
My son helped me lift off the hood and followed me in the truck for a quick 5 mile loop. We stopped and checked the trans fluid then he drove for another 6-7 miles.
Runs really well just trying to keep breaking everything in for now ran between 2,000-3,000 RPM.
The rear did make some alarming noises though when we turned? Seemed to get worse after we drove it a while. Hopefully the some figure 8s and let it sit overnight will correct it. I'll check with the rear end guy and see what he recommends.
View attachment 1174252

Is it a fresh build in the rear third member? Is it a factory sure grip? If so, add some friction modifier to the gear oil. All the auto parts stores sell it.

 

[Don Frelier]

I talked to the guy that built it. He gave me a bottle of Yukon additive when I filled it. He's sending me a couple more and he was pretty insistent that it should be filled til it runs out the fill plug and not with 4 pints which is what the service manual lists.
He said to use GL-5 80w90 non synthetic which is what I filled it with. I used the "Peak" brand which also says limited slip on the jug.

 

[Don Frelier]

I fixed the transmission fill tube leak on Wednesday evening and cleaned/painted where it had sat on blocks on the rear frame rail for nearly 5 months.
The rear axle guy sent me two more bottles of Yukon additive.
I put it in after work yesterday and drove it home (7mi).
It was a little unhappy on the last two turns.
Drove it to work today (14 mi) and just a slight groan turning into the lot.
Looks like it will improve with use.
It runs stronger than any 383 I've had or driven haven't even pushed it at all yet.
Let's see how patient I am...

 

[qkcuda]

Looks great Don. You're already more patient than I was.

 

[Don Frelier]

The whole drivetrain is new, something I've never done before so given the time and money I'm going to be careful for a while.
So far the cam/lifters seem to be mating up well which was my biggest concern given the reports of cam lobe failure going around.
It has just a little more valvetrain noise than the mopar .455 cam but this one has more aggressive ramp rates.
It snarls above 3,000 rpm but that's about as far as I've pushed it.

 

[Don Frelier]

Pretty amazing stretch of weather here in upstate New York the last couple weeks. Low 70s almost every day, dry and mostly sunny.
I drove the car to work 5 days in a row something I don't believe I have ever done before, nonetheless in October.

My son carried the extra hood down the hill. Its probably been up there for 4-5 years.
Still in ok condition.
I took some measurements off the satellite in the barn and scribed the opening. I was going to use my sons plasma cutter but I messed up the tip.
Luckily I'm pretty good with a Jigsaw.

I have a large hemi scoop to add on next.
Hopefully I get it all mocked up and I'll take it over to the local body shop.

 

[Don Frelier]

Well the test fit on the hood was off a bit, apparently the mark from whatever engines air cleaner stud doesn't match the 383. So we had to do a little massaging.
But a little plasma cutter and a grinder and we're good.

 

[Skytrooper]

Looking good !!!