Don's 1969 Charger Restoration

[747mopar]

Not surprised but at least I one upped you on something (I removed the whole entire roof) haha. You better buy stock in welding wire cause your gonna need allot of it.

 

[mopar4don]

747, Um, I plan on taking the roof off and blasting and epoxy priming! And I should buy stock in Blair spot weld cutters!

 

[CharGer]

I just bought a set of drip rails so thanks Don, now I know what I'm in for. I'm tired just thinking about it.

 

[747mopar]

Ok maybe I didn't, here's a pic of the roof surgery on mine. I don't even think this pic is on my thread but the vinyl top rotted out the front and rear window openings. Replacing it all was probably allot easier than just the skin.

 

[Coronet66JJ]

there is a thread for a restoration on a 69 six pack RR that I have been following . The guy doing the work is a professional and very helpful with questions. I learned a lot about proper welding skills and surface prep after the welding is done in order to prevent the new welds from rusting out. It seems that the heat caused by welding actually weakens the metal and can cause cracking adjacent to the welds if not done carefully. Good luck to you on this ambitious project, Don.

 

[Darius]

I feel your pain Bro!



I think I spent about $500 on spot weld cutters and use 2 1/2 rolls of wire. Just know it is sooooo worth it when done from a personal accomplishment perspective.

 

[mopar4don]

Ok maybe I didn't, here's a pic of the roof surgery on mine. I don't even think this pic is on my thread but the vinyl top rotted out the front and rear window openings. Replacing it all was probably allot easier than just the skin.View attachment 173529

747, WOW, now this is an interesting picture! How in the world did you get the roof off without messing up the quarters? And the same thing up front with the a-pillars. Looks like you just sliced them just below the top of the vent wings! WOW, I love seeing how guys do this!

there is a thread for a restoration on a 69 six pack RR that I have been following . The guy doing the work is a professional and very helpful with questions. I learned a lot about proper welding skills and surface prep after the welding is done in order to prevent the new welds from rusting out. It seems that the heat caused by welding actually weakens the metal and can cause cracking adjacent to the welds if not done carefully. Good luck to you on this ambitious project, Don.

Coronet66JJ, I'm interested. Do you have the link?

I feel your pain Bro!

View attachment 173540

I think I spent about $500 on spot weld cutters and use 2 1/2 rolls of wire. Just know it is sooooo worth it when done from a personal accomplishment perspective.

Thanks Darius!

 

[747mopar]

It's actually pretty easy to get it off this way, just drill out all of the factory spot welds inside and out where the quarters stop and it slides right out. When I did the pillars I wasn't sure whether or not I was going to pull the cowl so I just butt welded them leaving a 1/16" gap for a 100% fill weld. Go figure I later pulled the cowl and replaced it too but the roof I bought didn't go all the way down anyways. I feel for you, mine was pretty bad up top and in the trunk but otherwise was a really solid car only needing some minor pin holes welded shut in the floor boards. Like you I blasted it all and used Epoxy Primer to seal it up "good stuff". Love your thread, hard for me to gripe after seeing what your having to do.

 

[69 Charger RT/SE]

there is a thread for a restoration on a 69 six pack RR that I have been following . The guy doing the work is a professional and very helpful with questions. I learned a lot about proper welding skills and surface prep after the welding is done in order to prevent the new welds from rusting out. It seems that the heat caused by welding actually weakens the metal and can cause cracking adjacent to the welds if not done carefully. Good luck to you on this ambitious project, Don.

Yes Coronet66JJ, please give us a link to this build.

 

[mopar4don]

Drivers side drip rail

Time to update, Here I got the drivers side drip rail removed!







More patching will be needed.



Then I drilled out the spot welds along the front windshield channel and rear glass channel. (sorry I didn't get any pics)
Here are some pics showing the roof skin removed

 

[Ron 73]

Looks like some nice neat work you did getting that off! Some por-15 maybe! I seen you want to buy stock in the Blair spot weld cutters, they do work good! I see they changed them since i last bout some, my last ones had like a nail in the middle to hold them in place and the new ones i just got have a drill bit deal, hopefully better! Great work your doing bud!!

 

[747mopar]

What a ridiculous amount of spot welds that had to of been, are you putting them back on or leaving it shaved of the drip rails. So, how long until you start going forward instead of backwards.......you know......putting it back together?

 

[Propwash]

View attachment 175942


They made a Charger convertible?




Quick question fella's, seems like a good time to ask. To remove just the roof skin, would one need to remove all of that drip rail panels to do so? Never done a roof skin myself (just patches), and I will being doing one in the real soon future on a dart.

 

[hunt2elk]

You are an animal Don - in a good sort of way.

 

[mopar4don]

Roof SURPRISE!

After I removed the roof I found something interesting.
I actually noticed it while taking this picture!



Do you see it?
It's laying in the upper rear roof bow.
Go ahead look again!

Ok here is a better picture





Apparently someone was fixing the car and had a little trouble.....:buffer:
and decided to leave some tools of the trade.

- - - Updated - - -

Here is the replacement roof and a-pillars I picked up last summer.
Not sure yet if I am going to de-skin it or try to morph it in.
Right now I am leaning on de-skining it.
Any thoughts?

 

[CharGer]

Not knowing how solid it is, de-skinning it would ensure that all surfaces can be cleaned up and primered before putting on a new roof skin. It has to be the better way to go compared to what you have, just sayin. I say go for it.

 

[mopar4don]

I agree with you CharGer, I was thinking I would blast and fix the roof support then put the roof skin on.
Besides, I need to have something left of the original car!

 

[mopar4don]

Patching the Roof Support on the passenger side

I took some reference pictures of the rust damage on the passenger side roof support.
This would be in the back sde rear window corner.

Roof 2 quarter panel bracket
The quarter panel gets welded to this.


Had 2 remove it to fix the nasty metal under it!






Then I used tape to layed out where I wanted to remove the heavily pitted and rotten metal



And cut out my 1st patch for this area



Took the patch and flattened it out, then transfered it to some new metal.
I went back and forth cutting and fitting the patch to the opening I had cut out.
Actually the new metal for all of the patches came from the roof I cut off. It is the same thickness.
I checked it with a micrometer.







Notice the line representing were the bend needs to be



I put it in my vise aligning the marked line to the vise jaws.
I then hammered it over to create the 90 degree bend. (sorry no pictures)
Finally got it to were it looked pretty good!



Then welded it in!



Don't turn that dial!
Tune in again on this same BAT channel for more sheetmetal surgery!

View attachment 179473

 

[hunt2elk]

I know it is a small piece Don, but it sure must feel good to finally be welding in new instead of tearing apart.

 

[Richard Cranium]

Ok maybe I didn't, here's a pic of the roof surgery on mine. I don't even think this pic is on my thread but the vinyl top rotted out the front and rear window openings. Replacing it all was probably allot easier than just the skin.View attachment 173529

http://www.youtube.com/watch?v=YGxCZ8dsr3M