Don's 1969 Charger Restoration

[mopar4don]

Ok, so I figured I needed some templates to help me fix the nose of these fenders.
I have another fender that has a good nose so I layed out a grid on it and made templates that would match each grid line or section line. Sorry didn't get a good pic, but you can kind of see the grid in this pic

Next I made the templates (each one corresponds to a section line)

I then transferred the grid to the fender

These next pics show the template along the section line and you will see how far off the metal is. the same templates were used for both fenders. NOTICE how the pics of the grey fender were taken from above looking down. And the pics of the black fender were from below looking up.

 

[mopar4don]

some more...

 

[SGTPaul]

Good thinking Don! I did a similar thing with the templates when I fixed my fenders.

 

[mopar4don]

Thanks SGT,
Time to make a patch for the nose of the drivers side

Also made the inner patch

 

[mopar4don]

Next I had to cut out the bad area in the fender and then use the shrinker to form the outer contour

I also added the wrap around shape of the nose to my templates.
Here you can see two more layers that I stapled together. I need this to help me with the shape of the nose and "inner flap patch"

In this pic you can see the inner flap and the contour was matched to the outer patch using a stretcher

So after fitting the patch, (grind, fit contour, REPEAT, and REPEAT and REPEAT)

I welded it in

Once it was welded in I could fit the "inner patch" using the wrap around templates
(I used magnets to hold the patch)

 

[threewood]

That is some nice fab work!!! I love that you are saving the old panels by doing some metal repairs. For me, that was about the funnest part of my rebuild.

 

[69 GTX]

If you have harbor freight store close the have shrinker/stretchers for metal. Helps with contours.

 

[mopar4don]

Yes sir. I ended up getting them from eastwood

 

[69 GTX]

They sure are handy!

 

[SGTPaul]

Holy crap Don! U b the man!

 

[showard]

Repeat, repeat, repeat. Sounds like the way it always goes. Lots of work. Thanks for the pictures, they will help me for some work that I need to do.
Great job by the way!

 

[mopar4don]

Thanks for the comments,

So after welding in the nose patch, I noticed a problem in the front profile of the patch
(view as if you were standing at the side of the car)

So I made another template from my good fender (view from inside of fender)

(view from outside of fender)

No other way but to slice it, and gap it to fit the template

 

[mopar4don]

The pass side fender was not as bad, I cut the inner flap from the nose (like the drivers side) and ended up making a tool to hammer out the nose. (sorry no pics of this process)
I did layout the grid and used the same templates to get the nose shape correct.
I took all fender components and blasted them

 

[mopar4don]

Ok, next the drivers fender has this bad area

and I have a 68 junk fender that is good in that area,

so........ a slicing we go

 

[Don selleck]

great fab work!

 

[threewood]

Nice work!!

 

[mopar4don]

Thanks Don and 3wood,
The problems with these fenders just seem like they wont end! But I think I see light from the end of the tunnel!

 

[69 GTX]

Great progress.

 

[mopar4don]

Still trying to get caught up.....
Got the fenders and related pieces epoxy primed, along with the front valance and subframe connectors

now to put the fenders back together
1st I welded in the cowl/antenna bracket

before I removed this I had drilled 1/8 holes to help locate it when it goes back together (look by the vise grip) I try to think ahead lol

Then I welded in the rear brace

 

[daytona kid]

Great looking work! Some familiar repairs., some deja vu. But, you did a lot more than me.