69 Roadrunner - For the Boss

[EJL]

While the RR is at the dipper, I talked my brother into doing some metal replacement on his charger that’s been sitting in my barn for years collecting dust. He’s been collecting new metal for this one for a while now and I figured we could work on both cars at the same time going back and forth. He’s in no rush to get it done, but I’m helping to nudge him along.

First thing on the list was cutting out front floor pan. All the frame rails are in excellent condition. Nothing like the rust issues I had on RR.

Blue helped unwrapping new floor pan. How small of pieces can he chew the bubble wrap into I wonder??

Before we install new pan we cut out a section of firewall that was rotted pretty bad. Looks as though the heater core was leaking or something causing the firewall to rust out. Going to fab a new piece and spot weld it in.

 

[EJL]

Picked up the runner today from the dipper. It turned out as expected, only a couple of spots that need some repair before hanging new metal.

 

[EJL]

Well upon further inspection, there are a couple areas that are worse off than I thought. Driver side rear frame rail is shot. Too many pin holes along it to try and repair so it’ll need replaced.

I also realized now that the inner and outer wheelhouses are welded every 1/4” or so versus the normal spot weld distances, so it’s going to be difficult to just replace outer on that side. I’m already planning to replace both inner and outer on driver side so I may as well get the other inner.

Going to order those tomorrow so I figured I’d start hanging doors and fenders back on. Will install hood as well so we can get all the gaps and alignment right up front which should help when hanging new quarters for their alignment.

 

[EJL]

Removed wheelhouses on both sides yesterday. I need to screw inners to outers and clamp in place to see how they fit. Probably a smart idea to leave them un-welded until trunk floor and quarters are test fit???

 

[Dad's69RR]

EJL I have a ton of additional parts from my resto. When you get closer DM me I am in central Ohio.

 

[EJL]

EJL I have a ton of additional parts from my resto. When you get closer DM me I am in central Ohio.

Will do, thanks!

 

[EJL]

Finally got driver side rear frame rail replaced. Also cutting out and patching a few other smaller areas that were thin.

 

[EJL]

Driver rocker had some pin holes so cut out a section and welded in yet another patch.

With frame rail replaced, I got new cross member welded into place.

Wanted to weld on bumper reinforcements to new cross member, but there’s a significant gap at ends. AMD cross member not stamped at correct OE position??

 

[RT68440]

The car looks great! The metal replacement part of the project is tedious but very rewarding. Looks like we had our cars dipped and e coated at the same place...

 

[EJL]

The car looks great! The metal replacement part of the project is tedious but very rewarding. Looks like we had our cars dipped and e coated at the same place...

Yes, same place. Across the highway from Detroit airport.

 

[EJL]

Process of fitting new metal has begun. Lots of tweaking remains, but making progress.

 

[BradleyJ]

Good work. I've read your thread and am following. I'll be into this soon with a 68 gtx

 

[EJL]

Good work. I've read your thread and am following. I'll be into this soon with a 68 gtx

Thank you.

 

[EJL]

Progress update. After fitting wheelhouses, trunk floor, rear panel and quarters, we drove tech screws into each panel as locators before removing so we put back on in same location. We then pulled everything off to start welding.

Started with wheelhouses , cleaned metal, applied weld thru primer, installed screws and welded. We were fortunate enough to know someone who has a spot welder so we used that.

The spot welder made it really nice for marrying up the inner and outer wheelhouses. It saves a ton of time obviously.

Then we used screw locations to mount back on car and wire welded in place.

Next step is to prep trunk pan and weld in.

 

[ct71rr]

Your project is coming along nicely. Looks like we’ve done just about same amount of work as each other. I also used a spot welder on my wheelhouses. Saved a ton of work and time.

 

[chargervert]

You are really making progress on the metal work! Looking good!

 

[Nxcoupe]

Progress update. After fitting wheelhouses, trunk floor, rear panel and quarters, we drove tech screws into each panel as locators before removing so we put back on in same location. We then pulled everything off to start welding.

Started with wheelhouses , cleaned metal, applied weld thru primer, installed screws and welded. We were fortunate enough to know someone who has a spot welder so we used that.

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The spot welder made it really nice for marrying up the inner and outer wheelhouses. It saves a ton of time obviously.

View attachment 1374258

Then we used screw locations to mount back on car and wire welded in place.

Next step is to prep trunk pan and weld in.

Did your friend make that jig himself for the spotwelder? It's a pretty cool idea using the foot pedal to activate the spot welder and putting pressure on the welds to hold them tight. Impressive.

 

[69bird]

You want to do another roadrunner I'm so jealous it it looking great

 

[EJL]

Did your friend make that jig himself for the spotwelder? It's a pretty cool idea using the foot pedal to activate the spot welder and putting pressure on the welds to hold them tight. Impressive.

Yes he did. He’s a lot more advanced with doing metal work and fabrication. Just glad to know him and be able to borrow.

 

[EJL]

You want to do another roadrunner I'm so jealous it it looking great

Too many projects, not enough time. My brother and I already have two more in the pipeline. Wish I could help you.