the duster

[dusterbd13]

i introduced myself and my car in the new members forum, but i figured now that its mostly done and on the road, id start a project journal for it. figured id start from the biginning of my involvement with the car, so if y'all get sick of it, let me know.

my father got it for my from a guy in south carolina when i was 14. the dealership sticker on the taillight panel was stamford conneticut. when purchased, it was a 318, 3 on the floor, 3.23 sure grip car. deluxe interior, deluxe wheel covers, numbers matching, somewhat origonal. also not a straight panel, good interior piece, or not worn out part on it. we paid 600 for it, and that was 1996. my father started to tech me how to work on cars on this vehicle, as well as taught me how to drive in it.
https://static1.pt-content.com/images/pt/2007/10/d8-1.jpg
https://static1.pt-content.com/images/pt/2007/10/d4-1.jpg
https://static1.pt-content.com/images/pt/2007/10/d6-1.jpg
https://static1.pt-content.com/images/pt/2007/10/d2-1.jpg
https://static1.pt-content.com/images/pt/2007/10/d3-1.jpg

these pictures show the car after the first 600 paint and body job. all bondo, man. but i was in highshcool, and thats what i could afford. looked great with good wax and armorall. we also "restord" the interior so it would be nice to drive. there are also picture of my first engine swap at the age of 16. after driving the car for a few months, i managed to kill the 318. dad picked up a 360 out of a PA cop car from a friend of his in Kane, PA. i actually got to play hookie from school to drive to PA to pick up my engine. ran pretty good, until i killed it.
https://static1.pt-content.com/images/pt/2007/10/d10-1.jpg
https://static1.pt-content.com/images/pt/2007/10/d16-1.jpg


in 2000, i was being a moron, running hard with a buddy of mine hight behind me. a person pulled ou in front, i slammed on my brakes, he didnt. pushed the back end in 18 inches. trashed everything from the doors back. at that point, i almost left the car for dead.
https://static1.pt-content.com/images/pt/2007/10/844532R19A-1.jpg
https://static1.pt-content.com/images/pt/2007/10/844532R18A-1.jpg
https://static1.pt-content.com/images/pt/2007/10/844532R16A-1.jpg

[dusterbd13]

in 2003, i decided to bring the car back. i swapped on some discs off of a 73 duster, big bolt back axles, and 15 inch wheels and tires. then i started the body work. i did my best for a year or so, welding in th subframe connectors, new floor pans, trunk pan, taillight panel, quarters, and starting the mudwork on the front fenders and doors. that was before i learned that i could do metalwork, but havent the patience or feel for mud and paint. so i blew it completely apart so a friend of mine could do a paintjob and finish the bodywork for me in 04.
https://static1.pt-content.com/images/pt/2007/10/dusterbefore-1.jpg
https://static1.pt-content.com/images/pt/2007/10/CrawforR10072-1.jpg
https://static1.pt-content.com/images/pt/2007/10/CrawforR104923-1.jpg
https://static1.pt-content.com/images/pt/2007/10/dusterbeforemotor-1.jpg
https://static1.pt-content.com/images/pt/2007/10/dusterhackwiring2-1.jpg
https://static1.pt-content.com/images/pt/2007/10/HPIM0071-1.jpg
https://static1.pt-content.com/images/pt/2007/10/dusterbefore2-1.jpg
https://static1.pt-content.com/images/pt/2007/10/dusterbefore3-1.jpg
https://static1.pt-content.com/images/pt/2007/10/dusterundercarriage-1.jpg
https://static1.pt-content.com/images/pt/2007/10/dusterbeforeinstruments-1.jpg
https://static1.pt-content.com/images/pt/2007/10/dusterrearleftsusp-1.jpg

a year and a half later, the car was in worse shape than i dropped it off in. he had gotten married, took a promotion, moved, and had a kid. the car sat. so my dad and i got it back, and took it to roger hatly, a guy in my church that does bodywork. he finished the body, and took it to micky culp to do the final blocking and painting. in march of 06, it was returned. took 4 trips to get all the parts back to the shop.
https://static1.pt-content.com/images/pt/2007/10/dusterfreshpaint-1.jpg

[dusterbd13]

i rebuilt it slowly. did dynamat and my wife added foil backed jute to the entire interior. we reused the carpet from when i drove it in high school, and had medlin's upholstery put in the headliner. the dash grew up from the red painted stocker (what was i thinking) to a 69 cuda bezel loaded with autometer gauges. i used a dash cap on the pad due to financial constraints. after the dashwas wired and installed, as well as most of the firewall components hung, north state auto glass put in the front and back glass for me. after that, i wired up the whole back of the car with an EZ wiring kit i picked up at the swap meet. stopped at the firewall bulkhead. then i slid under the car for a while. refinished the gas tank, refinished all the rear suspension components that i had done poorly before the paint and body. i reused the 3.91 sure grip. put new bearings on the moser axles, and swapped on 11X3 finned drums from a cop car. hung an addco 7/8 rear bar. 6 leaf 340 springs, and KYB shocks on it. used stainless hard and flex lines throughout. hung the back bumper and taillights that came with my rear clip after making them look as good as possible, and wired up the trunk mounted battery and external kill switch.
https://static1.pt-content.com/images/pt/2007/10/rearend3-1.jpg
https://static1.pt-content.com/images/pt/2007/10/HPIM0072-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture042-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture1132-1.jpg
we then moved into the interior, finishing that by putting in the seats, door glass and regulators, weatherstripping, stereo, heater, etc. most of the parts are either cleaned up and recycled from the origonal interior, or gotten for cheap off something else. the door panels are actually 72 pieces that were blue, and re-dyed. kick panels are cut for blaupunkt component speakers, front bech was covered in JC whitney upholstery in high school, and a grant steering wheel that i liked on the shelf at autozone. the interior was intentionally left to look mostly stock. thats why the shift light mechanism is hid in the glove compartment, etc. didint want to deviate much on how it looked as my first car.
https://static1.pt-content.com/images/pt/2007/10/HPIM0065-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture1278-1.jpg
as all this was going on, we decided to "freshen" the motor. my dad and i tore it down. knew we were in trouble when we found large pieces of ring and piston in the oil pan. wound up with 3 flat lobed, 1 cracked piston, 6 broken rings, and two sucked valves. i beat that motor to death. the only salvageble things in it were the block, crank, and timing chain cover. even the distributor was worn. so we dropped it off at the machine shop and ordered eagle i beam rods, forged probe pistons, a comp solid roller, edelbrock victor jr, and a set of indy modified edelbrock heads. i had Kevco make me an oil pan with a crank scraper, windage tray, and all sorts of trap doors and bafffles. spent a while cleaning up casting flash and modifying a set of stock valve covers to clear the vlavetrain.
https://static1.pt-content.com/images/pt/2007/10/HPIM0076-1.jpg
https://static1.pt-content.com/images/pt/2007/10/paintedincompletemotor-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture008-1.jpg

[dusterbd13]

i rebuilt the front suspension again, this time using 11.75 rotors from a cordoba, 76 duster calipers, 73 duister spindles and steering linkage, boxed lower control arms, american muscle adjustable strut rods, poly bushings, KYB shocks, braided stainless lines, big block torsion bars, addco 1 1/8 sway bar, and a diplomat power steering setup.
https://static1.pt-content.com/images/pt/2007/10/JennMikesweddingbyCC006-1.jpg
https://static1.pt-content.com/images/pt/2007/09/JennMikesweddingbyCC015-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture074-1.jpg
my dad and i dropped in the motor with through bolted mounts and stock brackets after it was painted. we used a spec stage 2+ clutch, stock flywheel, and lakewood bellhousing. backed it up with the 4 speed from high school, stirred by a swap meet hurst shifter. used an internally regulated 105 amp GM alternator, summit fuel pump, high flow water pump, and aluminum radiator. wound up with cooling fans from an 80's new yorker. we also used TTI ceramic coated headers and a 3 inch TTI x-pipe exhause with dynomax mufflers. the first carb was a 600 edelbrock, but we couldnt get it to idle with the cam, and now its a 750 holly double pumper with a one inch four hole spacer. all this is under a 17 340 air cleaner.
https://static1.pt-content.com/images/pt/2007/10/Picture018-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture009-1.jpg
https://static1.pt-content.com/images/pt/2007/10/HPIM0068-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture021-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture022-2.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture037-2.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture068-1.jpg

[dusterbd13]

we bolted the front sheetmetal on, using a flat bolt on fiberglass hood, 73 duster fenders, and the best grille we could find.
we are now in the shakedown/cleanup/make it work better stage. it doesnt handle like i want it to, the interior needs some more attention, bumpers need rechromed, and it needs tuned in. other details need to be adressed too. hope y'all like it.
https://static1.pt-content.com/images/pt/2007/09/Picture143-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture141-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Picture12551-1.jpg
https://static1.pt-content.com/images/pt/2007/10/Engine-1.jpg
https://static1.pt-content.com/images/pt/2007/10/GuageCluster-1.jpg
https://static1.pt-content.com/images/pt/2007/10/DusterSky-1.jpg
https://static1.pt-content.com/images/pt/2007/10/DusterProfile-1.jpg

Michael

[Smock67]

That is sweet and a nostalgic look too. So from your plans looks like
re chrome bumpers
freshen the interior
get it too handle

Sounds good man.

[dusterbd13]

yeah. probably going with a FFI stage 3 box, tubular UCA's, and stiffer springs front and rear. may also look into 17 inch steelies to keep the vibe, but dont know how they'd look.
get the seats redone and replace the carpet
straighten chrome the bimpers.
see if i can get it into the low 12's, still handling great and driving anywhere.
Michael

[Rantheman]

nice I like dusters I had a 1970 twister with a v8 swaped in it. it was orange with black strips

[Tony_SS]

I'm not a Mopar guy, but I really like the build. Nicely done and it does keep the original feel for the car.

[Young Gun]

looks cool...fun project!

[dropit69]

Man thats Sweet !! love the Dusters great job !!

[Chevrolaine]

Great job! Way to keep at it.
Guess we all know who your first love was.:razz:

[dusterbd13]

so the FFI stage 3 box shipped today, and ive gotten the carb rebuilt. still need to fine tune it, as its running a little lean and has some hesitation.
also, ive gotten the clutch linkage debugged, turns out that i missed a return spring when i put it together.
once i get the box in, i'll get it re-aligned with some more posttive caster and negative camber and see if i can get it where i want it.

im also looking at new wheels due to the photoshop experts here, primarily these two if i can find them:

https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

im also looking into 1 inch t-bars and new rear leaves from firmfeel while im at it.

dunno. just thought i should update someone on my project.

Michael

[Z06killinSBF]

PS looks great. Nice and low.

[LMDGUY]

the over size steel wheels look kinda cool.. kinda sleeper looking

[Krazed]

If you're looking for Handling and steering stability, might I suggest something?

Tubular Upper control arms. The new ones have far better adjustability, including built in positive caster to help strait line stability.

I put these on my 68 Barracuda, and they fit perfect, and look great, and work wonderfully.

http://www.capautoproducts.com/Control_Arms.html

Other then that, I like the Duster so far! Just beware, don't go too low with those TTI's, I have maybe 4" ground clearance with my 3" TTI Headers + exhaust.

[dusterbd13]

yeag, the photoshops are actually way too low. at that ride height, id have to build a new exhaust, or my current one would be flat.

i agree with the tubular uppers being the way to go, but out of a sense of masochism or something, im trying to see how far i can go with factory style stuff first. only change so far is adjustable strut rods, but only cause mine were seriously bent.

im still trying to find someone to make 17 inch steelies. stockton makes 16....

Michael

[High Plains Mopars]

im still trying to find someone to make 17 inch steelies. stockton makes 16....



I'd actually try to avoid that if possible, the additional weight of a 17" steel wheel will be large enough to have a pronounced feel on acceleration, braking, and handling. They weigh a freakin ton.

[Young Gun]

theres gotta be some company out there that makes some lightweight wheel that looks like those...

[ill steez]

on that car, i really like the look of the big steel wheels... i'm sure someone makes an aluminum wheel like thatm that you could just paint or powdercoat to match.

[Mr.VENGEANCE]

dont you just love threads like this!..

[dusterbd13]

if someone has a company in mind that could make those wheels for a REASONABLE price, let me know. thats the way im leaning heavily. 255/55/17 on the back, and the 17 inch equivilant of a 235/60/15.

still gotta figure out the backspacing, though.

anyway, thanks for the positive comments.
and Mr. Vengance, why do you love threads like this?

Michael

[Nate K]

Tubular uppers look cool but you can do the same thing with offset upper bushings. I get them from napa for about $40 and can easily get up to 6 degrees of positive caster. I run mine at 4degrees and it makes a huge difference in handling.

[quote=Krazed]If you're looking for Handling and steering stability, might I suggest something?

Tubular Upper control arms. The new ones have far better adjustability, including built in positive caster to help strait line stability.

[matdean]

Wheel Vintiques www.wheelvintiques.com/ Makes 17" Steelies, but they arent cheap. I am sure they do weigh a good bit too. (You can buy them through Summit.)

[molyorange 77]

I like the steelies idea they look great! And I like that you painted the aluminum heads and intake. I did the same thing on my chevy but the single plane gives the sleeper look away!! HEHE:naughty:

[dusterbd13]

so i finished the FFI stage 3 box today, and all i can say is that i love it!! the car drives a thousand times better, and the steering feels much like my Mazdaspeed now. no on center dead spot any more. the car still has no initial turn in or steering wheel return, but thats all in the alignment. may go with tubulars, may not. havent decided yet, and wont until i see what i can get out of the stock uppers.

next step is to replace the fragged speedo, readjust the shifter, and get some more miles on it while tuning in the carb. by that point, maybe i can afford some 17's. anytone wanna buy a chrysler cirrus with a bad trans? that way i can get my wheels.

anyway, just wanted to gove the update, and the glowing results of my purchase.

Michael

[dusterbd13]

got the car dyno'd a couple of weeks ago, as well as fine tuned. much more drivable now. and it actually idles!! yay!!
we found that i had snapped a couple of pushrods, the parts store distributor never actually advanced, etc. i should have found these myself, but after it quit on me the last time i drove it, i got fed up and left it under the cover.

anyway, ater fixing and tuning, it made 386HP at 5500, and avereaged 350+ lb-ft from 1800-5500. peak was 399.

figured id give a small update. now that its driving again, maybe ill mess with it some more.

Michael

[blown9746]

Love this car. Would definitely go with the steelies. They just look right on this car.

[ALLstrokedOUT]

Nice! i must have looked at this build a couple dozen times over the past year as motivation or reference. Good numbers from the dyno too!

[dusterbd13]

thanks for the positive comments, guys. its not too often that a car with 15 inch eheels, a bench seat, and a 4 speed gets love on this board. im actually really enjoying driving this car now, and after playing with tire pressure some its handling a lot better.

Michael

[maldo]

Man you really did a nice job on your ride .... i would keep it as stealthy as possible .........

do you have any video sound clips of the car .....

[dusterbd13]

nah, no video or sound clips. i actually am not sure if my wife's digital camera takes them, and then wouldnt know how to post it. if i ever do get some, ill be sure to post it.

Michael

[The Stickman]

I'd actually try to avoid that if possible, the additional weight of a 17" steel wheel will be large enough to have a pronounced feel on acceleration, braking, and handling. They weigh a freakin ton.


Try Wheel Vintiques. They have some on 17 inch in steel and billet.

http://www.wheelvintiques.com/shopsite_sc/store/html/index.html

[icebird84]

good looking stock Duster

[Johnny C.]

Cool project. I like what you are doing with it.

[dusterbd13]

icebird84good looking stock Duster

thanks. its really not that stock though.
could go further, just havent. been having too much fun with the driveabeater.

right now, im just enjoying driving it. when the track opens back up, ill see what she'll run in the quarter.

Michael

[dusterbd13]

ive been driving it a lot lately. to work, to daycare, to my second job, to church, etc. almost a nice day daily.

that has uncovered teething problems, as well as things i just dont like and annoy me.

1. the speedo didnt work. after moving some wires around to eliminate the interference, and regrounding it, it works for the first time since the resto. its amazing what RPM i have to run to run the speed limits. which brings me to
2. the gears are just too stiff. at 3000RPM, with 28 inch tall tires, im doing 60 MPH. thats just rediculous. so i worked out a deal with hollis over at HP engines that im trading my 3.91's and 2.76 open diffs for a fresh 3.55 sure grip unit. clutch type. im excited. ill post pic when i get it from him.
3. i blew out another drivers side header gasket. ill be putting coppers in that side when i get the chance.
4. my alignemnt sucks. the pass side tire is rubbing the fender from where the last alignment tech lengthened the adjustable strut rod. i believe im going to try to align this thing myself. i do GM stuff all the time, as well as all my other cars, so i "should" be able to do this one.
5. ive had some electrical gremlins pop up. sub, drivers side brake light, and alternator all quit working at various times. alternator was a slipping pully from where the nut loosened. sub was a bad ground, and i havnt figured out the taillight yet. im thinking turn signal switch.
6. the shifter is vauge. its a hurts comp shifter, with the stops all set up, new bushings, shimmed for a good fit on the rids, etc. done right, just vauge. ill be looking for another solution at some point.
7. the hood prop rod needs reengineered. its a POS.


the only other real update is that i test fit a set of 17 inch mustang bullit wheels. i like them, and they fil really well without any spacers or anything. the rear will need a small spacer just for looks, as theyre a little too far in. as soon as i find a good set for a good price, ill be grabbing them. im also converting from manual to power brakes, as i jsut get tired of the leg effort required to stop this thing.

jsut wanted to let you know the car didnt slip into obscurity or get sold.

look for updates as i work on it.

Michael

[dusterbd13]

got the header asket done.

the TTI's have a known problem when they are bolted to heads that are ported to fel-pro gasket size. mine are. the current fix is to have the sealing bead welded in a different location and then milled back to flat. i really DON'T want to do that if i can help it. so my idea is (and we will see how it works) is to use a smaller sized copper gasket put in "wrong".

heres the carbon tracing on the head:
https://static1.pt-content.com/images/pt/2009/11/Picture028-1.jpg
https://static1.pt-content.com/images/pt/2009/11/Picture029-1.jpg

and the nuked gaskets i pulled out. i ran a set like these (fel-pro exhaust manifold gaskets for a 360) on my old blackjacks for years, as well as the hedmans in my old 84 ram. never leaked.
the ones off the TTI's
https://static1.pt-content.com/images/pt/2009/11/Picture030-1.jpg
https://static1.pt-content.com/images/pt/2009/11/Picture033-1.jpg

my idea on the undersized gaskets is that the embossed lip fits inside the port opening of the fel-pro gaskets. my theory is that the copper is thick enough to seal the header to the head withput the bead of weld. i turned the ebossed lip inwards so it would slip into the port on the head. on the initial fire up, is sealed. no carbon tracing yet. im going to heat cycle it a few more times before i put the locks back on and see how well it works. if it doesnt, i find another solution. next step is a 1/16 steel plate with the proper brading on one side, using the port opening dimensions of the TTI headers. use a pair of gaskets cemented to each side. it should theoreticaly be a bolt on soltion id the copper gasket doesnt work.

heres some pics showing the fit difference between the summit coppers and the fel-pro's.
https://static1.pt-content.com/images/pt/2009/11/Picture030-1.jpg
https://static1.pt-content.com/images/pt/2009/11/Picture031-1.jpg
https://static1.pt-content.com/images/pt/2009/11/Picture032-1.jpg

michael

[dusterbd13]

spnt a few hours swapping in my new 3.55 suregrip unit.
id have taken pictures, but nothing visually changed.


i still have some noise from the rear that i cant find. ill keep working on it. im beginning to think pass side wheel bearing.


also working on a trade for an 800 CFM eddy carb with a choke to get rid of this crappy holley while i scrounge the rest of the parts i need for my sleeper EFI conversion.


have to gove feedback on the 3.55 though. cruise RPM at 70 is 3000, versus the same RPM at 60. the midrange feels much better, and the gears seem to match the sweetspots in the powerband better than the old 3.91 set.

the headers are still not leaking.

thats it for the update.