Project Eh-Body - 1976 Plymouth Duster.

[Riddler]

I'm starting this thread to show you guys what I've been working on. I'm pretty slow on my build but it's coming along. I started the build back in Sep2009 and will post all the updates from another forum I have my build on. If it's too much, please let me know.

Thanks

Riddler

[Riddler]

It's a 1976 Plymouth Duster that my wife bought me. Yeah that right, my WIFe bought this car for me for my birthday. No she's mine and no she doesn't have a sister! LOL

This is what the car looks like when we brought it home...

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Overall a solid car from the USA. I'll be adding to this project long as time goes on.

Riddler

[Riddler]

First things first. The interior smelled like Moth Balls. It was used to get the mice out of the car since it was stored in a barn. The entire interior was removed.

One Seat removed
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Both Seats removed
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Rear Seat and Carpet Removed
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The only rust I've found so far. Also note the center hump has had another hump installed over it with screws and seam sealer.
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Driver's Side Rust
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Well the interior is out, I've located and purchased a set of floor pans. Not sure I'll need them since it's mostly surface rust. I can prolly make due just patching with some small sheet metal cutouts for the holes.

Total dead mice found - 4

The plan is have the entire car blasted.

Riddler

[Riddler]

Well I've started to disassemble the car down so that I can get it blasted.

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Front end gettig stripped down first.
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Fenders came off once we found all the nuts.
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Only surface rust. Woohoo!
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Riddler

[Riddler]

Well the disassembly continues. This time I went to the back of the car and started to remove everything.

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The gas tank was brand new. At least that's what I've been told.
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This is going to be a larger job. Someone in the past has screwed down another (Volare/Aspen) center hump over the stock hump. Then they seam sealed it. Gonna have to grind the screw heads off a peel this center section off.
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This concludes this disassembly installment.

Riddler

[Riddler]

Well I got alot more done this weekend. I'm also finally up to date on the pictures. This is how the car is currently sitting...

Look ma, no glass...
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Pictures of the glass out of the car.
Front:
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Rear:
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So this was my goal this weekend, to get the glass out. After about an hour I had it all out. So I went for bonus removal on items.

Started with the dash now since I could get to those bolts.
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I figured the column would be very troublesome to get out. Nope the old owner had taken all the bolts, pins etc out and left them out. Just a quick pull and it came.
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Now this this was all removed, we went to remove the brake booster and resivoir.
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Not much left to remove. Engine and tranny will come out when I can get a hoist. The rear end can come out anytime now.
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While taking out the rear quarter glass I found something strange. The driver's side has an extra piece of metal. How odd!
DRIVER'S:
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PASSENGER'S:
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This had to be a factory error. The piece of metal was not cut out unless god himself removed it. No evidence of cutting or anything.

Finally I've been asked how I keep track of all the parts. Everything goes into bags and bins!
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Riddler

[Riddler]

Well I jumped back on the disassembly of the Duster this weekend. I decided I finally wanted the Volare/Aspen center hump and shifter removed to see what is under it.

Here's me grinding the screws and seam sealer off.
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I went from this....
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To this....
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I then decided to remove the white peice of tin.
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Yes that is a piece of a My Little Pony lunch pail! LOL

After this was all done I had some more spare time, so I figured I'd empty out the doors.
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Finally both doors are ready for blasting.
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On Saturday 31OCT2009 I got a call about a motor. I jumped in my truck with my brother in law Jim and purchased that motor.

Here's a small teaser for now....
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Riddler

[Riddler]

Without further ado.....

2005 5.7L 345CI Hemi. This elephant weighs prolly 600-750lbs. Thank to Jim for the help geting her home.

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I'm hoping to find a 545RFE or something similar for behind this. I'm going to keep it automatic so my Wife can drive it also.

Riddler

[Riddler]

Haven't worked much on the car but I have been buying items.

Here's a factory correct console....

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I've also sourced a set of tail light from a gent in Texas.

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Last but not least is a complete rear suspension. Gone will be the old leaf spring suspension. This is an RMS Street Lynx kit.

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That's all for now.

Riddler

[Riddler]

Well here's the latest update. Not much has happened since the last update due to the fact I up'd and moved on Jan 26 and my wife and I have been working on getting settled. But things have to get moving if I ever want to see this project completed.

First thing was to start making more room for things. So I cleared all the parts out and made room for more dissassembly.

Here'e my 8 3/4" E body rear end with a 489 center section.
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With my brother in law away I had to recruite the help of my dad. Never had a chance to work with my dad on cars, but man it felt good, talking cars and about missed times...

Here's the 318 he helped my yank out.
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After this out I could see the full extent of the k frame and steering box. The steering box must weigh a metric ton. Looks big and heavy!
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After this was done I set up the rotisserie. I still need to get the car higher in the air and bolt it onto the rotisserie, but it's set-up and ready to go.
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Well until the next update....

Riddler

[Riddler]

Well I've been working on Project "Eh" body.

Since the last update of setting up the rotisserie, I've removed all the suspension, body plugs, clips, etc etc. This was done with the help of Keith Zimmer. Truely one of the car gods. Thanks Keith!

Rear suspension
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Front suspension and old brake lines
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So to complete the removal of all the body plugs, clips, etc we got to play whirl the Duster around!
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Well since everything was off it and Keith's blasting it for me, we decided to just take the car over there today.
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The truck showed up and it's loaded. Nice to see another Mopar hauling my Mopar!
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When the car come back next week it'll be blasted and epoxy coated. Then I'll start the metal work.

Riddler

[Riddler]

Well today I made it over to the media blaster's. He warned me that the fender's were no good. I was heart broken since I knew the car was practically rust free.

The fender's turned out to be not bad at all. Just has some minor waves in the driver's side and the passenger has a small hit in the front.

Passenger Side:
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I should be able to tap these out....

Driver's side:
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You can still see where the bondo is. He's going to finish up blasting the fenders of bondo and then I should be able to bang them back into shape.

He then showed me the hood and trunk lid. He said these are some of the best parts he's ever blasted. Barely any paint on them and they had practically no rust.

Hood:
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Trunk Lid:
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The last picture is of the car on the rotisserie waiting until all the smaller parts are done.

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Well that's all for now....stay tuned...

Riddler

[Riddler]

Well I started working some on the Hemi 5.7L to get it cleaned up and converted to a car LX motor.

I started by removing the truck manifolds, accessories and motor mounts.

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While trying to get the pulley bolt out, I broke it. WTF?

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Right now I'm at the point of getting a smaller puller 3 jaw puller. Once I get the pulley off, I'm hoping to be able to get at the bolt.

Riddler

[Riddler]

Well after waiting 8 long weeks, the Duster has arrived home. I'm eager to dig in on metal work but I know it's going to be a long slow process. I don't have an end date in mind, and honestly I see this as a project for a few years. Money permitting. :)

Here's what I have to work with after media blast and epoxy primer. The car has been hit on both sides very lightly. Both quarter's need work. The front floor pans are also pretty much shot. I have new one to put down anyway! Onto the pictures....

Full car shot on rotisserie
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Driver's side quarter with slide tool holes.
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Driver's rear seat belt mount. Both are sides are gone.
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Driver's front floor pan or whats left of it.
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Driver's front A pillar. The lead from the factory came out during media blast.
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Engine bay
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Passenger side front floor.
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Passenger side rear seat belt mount.
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Passenger side rear quarter. The only rust to the outside body panels. Small patch will fix this.
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Passenger side trunk extension. It looks like the previous owner jacked the car from that pinch weld.
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Trunk area clean
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and finally the roof with very slight dents.
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Now that I have the car back the plan is to work a small amount each day on it. I have to return the rotisserie so the plan is to make some stands with casters that bolt to the bumper bolt locations.

Riddler

[Riddler]

I haven't really done much since I've been parting out my Neon. But I have made some purchases.

This is a fuel door pocket off a newer challenger with the Retro look fuel door.

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The plan is to replace the stock Duster fuel door with this one.

Riddler

[Riddler]

Well as I'm sure you can tell, I haven't really started cutting metal and such. I have however saved up and bought some more parts.

Here's my front RMS Alterktion.

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Then since I went to a different spindle I needed new brakes. Wilwood had some really nice 4 piston Dynalites with 12.19" rotors.

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I'm hoping to be cutting metal soon. I've got alot to do. My goal is to have rolling chassis by xmas. :)

Riddler

[Riddler]

I started working on a few things. The first thing is cleaning up and fixing on the grill attachment points on my 75/76 Grill. I like this grill better than the 73/74 one.

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I also wanted to check out Evaporust. So I decided to soak the K-frame bolts to see how well they clean up. This is a picture of the bolts before.
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This picture shows the bolts in Evaporust.
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Stay tuned for more.

Riddler

[Riddler]

Picked up some more parts. I know I know, try and get some work done! LOL

Here's the front brace from XV Motorsports.
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I also sources a VERY RARE set of NOS 73-76 Duster tail light lenses.
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Riddler

[Riddler]

I bought some more parts, something new, something old, something shiny!

Lets start off with some more NOS parts. I found a set of 75/76 Duster Bezels and also the top trim.
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I then was walking around MoparFest and found these items both from the same vendor. Not a bad haul for $60cdn.
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The other one I had wasn't flawless so I seold it on ebay for double what I bought this brand new one for.

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Since I wasn't able to find any parts worth paying for at the MoparFest swap meet I decided to take a look at a couple of the hardware vendors. I found PENSTAR Reproductions (http://www.penstar.net) and the owner James really helped me find everything he had in stock for my car. Since he was from the states and I had US greenbacks I paid all in US and he cut me a huge deal.

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What you see in this pictures is:

Body Plug Set
Door Plug Set
2 OEM Chrysler ignition keys
2 OEM Chrysler trunk keys
2 Door pins
Front and Rear windshield clips
and the large package is a complete interior screw set.

I'll be ordering more from him to finish the car.

Riddler

[Riddler]

I haven't had alot of time to work on the car but tonight I found a couple of hours. Although it was used to clean up the garage some I did find the time to cut out my Challenger fuel door body mount and get it ready for welding.

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I'm hoping to clean up the garage more and mock some things on the car.

Riddler

[Riddler]

I told myself over the last week at work that I needed to start digging in and getting the Duster worked on. I decided if I could get a bunch of things ready for welding, maybe my welder (brother-in-law) will do some welding when he returns from a business trip.

I started out and got the rear Street Linx cross bar mounted. I still have to take it down now, use the flap wheel to clean off the primer so welding can be done!

I then started looking at the front floors in the car, yeah they look like crap, I have some new ones to install. I started by cutting and removing the front passenger side floor. After I fought with the spot weld bit for an hour I finally got the hang of it. I'd still like to find a better one.

Here's what the floor looked like after being removed.
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Here's the hole...
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As you can see my frame rails are in VERY good condition. I still think I'll brush in some por15 down them to keep the insides nice.
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I then tackled the center, and since it's not going back in, I just cut it out. Four spot welds is all that really held it in.
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This is what I'm left with. I had to stop as the cutting and banging was driving my wife nuts. :)
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Till next time...

Riddler

[Riddler]

Well the rest of the floor has been removed.

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I'm thinking I'm going to use POR 15 down inside all the frame rails to go over that rust and such. Then when the new floors are welded in the insides of the frame rails would be coated.

I've also been working on trying to get the front alkerktion k frame mounted but the stock bump stop and such are spot welded on really well.

Riddler

[Riddler]

Well my rims (Boze Pro Touring) came in this week. The fronts are 17x8, 5.5" backspacing. The rears are 18x10 with a 4.5" backspacing. I was really hoping to have more of a front dish but due to the brakes and such I'm required to use this size.

I purchased Falken FK452 tires, 245-45-17 for the front and 275-40-18 for the rear. I took the brand new rims to the tire shop in the boxes. The manager's assistance tried to put the front tires on. I say tried cause he marked up both front rims. HE didn't notice these were reverse mount style rims. Lucky for me the shop is going to buy me two new rims to replace the marked ones and I get to keep the marked rims anyway.

The manager installed the rear rims and had no issues at all.

Here's the pictures I snapped tonight....

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Guess I can finalyl measure up the rear end!

Riddler

[Riddler]

Well I got to work a bit today with the help of my brother in law Jim. Jim's great with metal and knows how to weld much better than me. The welding helmet had dead batteries so we only got tack welds done. Everything still needs to be welded in. We started with the RMS Street Linx. Sorry didn't catch a picture of this yet.

We then moved onto the passenger side front floor. This is what the front rails looked like after I used POR-15 a few days ago.
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Here's the panel just getting put in, I think there are 2-3 tacks so far.
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This picture shows what it looks like tacked in. It doesn't move at all. I need to get some autobody pinch weld clamps so we can have a nice pinch weld.
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Another view of the passenger side in.
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This is the driver's side panel with the holes for the spot welds. Lots of drilling going on!
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While I was drilling the holes in the driver's side panel and waiting for the rechargeable drill battery to recharge, Jim got to work on getting the new Challenger gas door installed.

Fitting the fuel door body ring and measuring a few times before cutting.
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After cutting Jim cleaned up all the burrs with a file.
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This is the fuel door body ring tacked in with the new fuel door. This was to check to see if it was straight.
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Well until next time...

The plan, finish the driver's floor, then do the subframe connectors and maybe relocation boxes.

Riddler

[Riddler]

Well time for a large update. I came home from work and my brother in law Jim came over. Jim takes welding and turns it into an art form. If I could weld and manipulate metal the way he does I'd be light years farther along.

Here's Jim welding the passenger side floor panel in. Remember it was only tacked in before.
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Here's the finished panel, just need to use the flap wheel to bust down the welds a little and then seam seal and prime.
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Jim then moved to the Street Linx main bar. Welded it in fully. I just need to get some primer now and prime it.
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Close up of the welds. It's not easy to weld with the car not high in the air.
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While Jim was busy welding the passenger floor pan and also the rear Street Linx, I was getting the front of the car ready for the AlterKtion. RMS states that those brackets are not welded very well, let me tell you, by 1976, they got better at welding, cause they were really on there. Picture of the brackets removed...
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Jim then assisted me in bolting the AlterKtion up to the frame and also drilling through and installing the helper plates.
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The driver's floor was prepped and Jim set about welding it in. Floors really are a two person job, one to stand on the floor and one to tack it in.
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While Jim was welding the driver's floor pan in, I set about building all the peices of the front AlterKtion. QA1 Coilovers...
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Here's everything set out on the bench so that I can start assembly. I guess once I know it all fits, I'll send most of it out for powdercoating.
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I still have a few things to do for metal work. I have US Car Tool subframe connectors, spring relocation boxes, and the dreaded minitub.

That's it for now.

Riddler

[Riddler]

Well I found some time tonight while my wife went out shopping. I started to assemble the front AlterKtion. It's so easy! I got the lower control arms on, the QA1 coilovers and the spindle. I've been stopped in my tracks as I don't have the stock bolts for the upper control arms. I now need to make a trip over to Mancini Racing since none of the local parts shops can get them.

Here's a pic to show where I'm at.

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Riddler

[Riddler]

Well today my brother in law and best friend Jim came over to work on the car. I started work on the hood hinges with gas struts and he started on the Willwood front brakes since I had the front AlterKtion assembled.

Here's the Willwood Dynalite hub and rotor bolted together.
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Here's the back of the rotor with the stainless steel safety wire. Jim is a master of this, I'm super happy to have a friend with these skills.
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Here's a picture of the front hubs with the bearings packed, the seals installed and ready to be bolted to the spindle.
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Here's everything bolted onto the car ready for some wheels.
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Now the front wheels. We bolted these down with just a couple of lug nuts since I want to buy some better lugs. These are just cheapy ones.
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Close up....
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While Jim was working on the front brakes I moved from the hood hinges to the XV front brace. I figured the chassis needed to get finished before I started to do little things. I cut and removed the stock sheet metal and cleaned up the front for welding. Jim welded the brace on for me.
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Then I primed the XV brace so it doesn't rust.
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So now the front brace was done, I turned my attention to the floor pans. The welds needed to be grinded down and then I needed to seam seal and prime them. The rust was starting....
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Now comes the seam sealer..
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Here's the floor pans primed. The primer matches the Epoxy Primer used by the media blaster.
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Just want to say thanks again to my brother in law Jim.

Riddler

[Riddler]

Large update for today. Jim came over and we tackled the subframe connectors and the relocation boxes.

We started with the subframe connectors. The US Car Tool connectors were older ones and didn't fit perfectly. We were required to massage them in and I still have some very large gaps, which I assume are for the ebrake cables.

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Here's the inside floor primer burning and the final burn marks before I primered over them again.

https://static1.pt-content.com/images/noimg.gif
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Here's Jim welding away...
https://static1.pt-content.com/images/noimg.gif


Then we moved onto the relocation boxes. Not very hard just time consuming.

https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif
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That ends another day....

Riddler

[Riddler]

I woke up very early today and made it out to the WPC swap meet in Mt. Clemens, MI. I scored some great finds.

First up is a pair of 5.7L Hemi chrome valve covers.
https://static1.pt-content.com/images/noimg.gif

I then found a repro seller who was very reasonable. I scored a complete set of marker lights.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

and last but not least a new set of door handles.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif


Riddler

[Riddler]

Well I got back to work on Sunday with my brother in law. He completed the last of the welding needed for the relocation blocks. While he did that I drilled and tapped the XV Motorsports front brace for the hood latch.

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

Then we moved onto the minitubs. While these are not really needed now I'm hoping to purchase wider rims and tires for the rear in the future.

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

Then we removed the driver's side...
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Lastly we made the passenger side match the driver's...
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Of course I just had to stick the rear rims/tires under it to see. Measured the rear also, 54 1/2" mounting flange to mounting flange.
https://static1.pt-content.com/images/noimg.gif

Plan is to be back at this weekend....

Riddler

[Riddler]

Well sort of a large update today. Jim and I and our friend Steve hit up Autorama Detroit this weekend and this really got our car juices flowing. So today we worked like crazy mad men!

Jim went right to work on the the minitubs. He grinded and welded and floor to the frame.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

While he was working on that I removed spot welds and then removed the floors from the tubs. After that was done I got snagged on a stud for the rocker trim. Grinded those right off.
https://static1.pt-content.com/images/noimg.gif

Jim and I got both tubs tacked in and solid enough for use to leave them. We were both sick of working in the grinding mess so we cleaned up.
https://static1.pt-content.com/images/noimg.gif
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One would think this is all we got completed today. But it was nice out and we worked with the garage door up. We mocked up the RMS Street Linx so I can have the read end cut down.

All laid out on the bench...
https://static1.pt-content.com/images/noimg.gif

Now the mock up shots.
https://static1.pt-content.com/images/noimg.gif
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Well that's all for today!

Riddler

[Riddler]

I've been keeping this under wraps for a few weeks while working with Shawn Mascoll of Mascoll Designs.

This is a rendering of the completed look for Project EH-body.

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

link to open in a new tab since DNO chops it off.

http://www.riddlerneon.com/gallery/albums/userpics/resizefinal.jpg

Riddler

[Riddler]

Well I finally got off my butt and opened the rear Wilwood Dyna-lite brakes with parking brakes. Good news is all the parts are there. The bad news is the calipers do not match the fronts. The rears are actually black and the fronts are what Wilwood calls "Platnium". Apparently Wilwood changed to platnium powdercoating for a short period of time and I was lucky enough to get a pair.

Rear are on the top, fronts are bolted on.
https://static1.pt-content.com/images/noimg.gif

The good news is, Bill Reilly at Reilly Motorsports Inc., is taking care of me. I've sent the platnium back to him and I'm getting a pair of black ones.

If anyone likes that platnium colour Bill now has a complete set of front and rears.

Riddler

[Riddler]

Anyway here's an update.

Here's the newest update. I took the rear housing over to Drive Train Specialties in Warren, MI and had them cut down the housing, weld on new ends, weld on the Street Linx parts while it was on a jig and then install the new bolts kit I bought.

I then brought it home, grinded off the welding splatter and other crap and gave the housing a fresh coat of POR15 chassis glass black.

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

Next I'll assemble the rear axle and finish the minitub.

Riddler

[Riddler]

Here's an update from today. I was able to find some time today to get the rear axle built and into the car.

Layed down a nice bead of Permatex Gear Oil RTV Sealant. Specially made for rear axles!
https://static1.pt-content.com/images/noimg.gif

Bolted on the center section. 45 ft/lbs
https://static1.pt-content.com/images/noimg.gif

Rotors and Calipers installed. They look great!
https://static1.pt-content.com/images/noimg.gif

What kind of axles are those? That's right, MOSERS!
https://static1.pt-content.com/images/noimg.gif

Assembled ready to go into the car.
https://static1.pt-content.com/images/noimg.gif

Here's one of the wheels on the car. Studs are too long for the style of lug nuts I have. Plan right now is to cut them down.
https://static1.pt-content.com/images/noimg.gif


So how'd I do?

Riddler

[Riddler]

So today I was able to get over to Inline Tube Inc. in Shelby Township. Let me tell you guys these guys know and understand brakes. I walked in expecting to have to explain everything. They looked at what I had in mind and went above and beyond.

In this picture you can see the green and white coat hangers I bent up for the rear axle. They took those and made CNC copies of them in stainless steel.
https://static1.pt-content.com/images/noimg.gif

I was then explained that since I've gone with Wilwood rear disc brake I should have some sort of flex lines as they tend to move slightly unlike stock drums. So I went ahead and purchased the rear flexline kit. Along with that I also purchased all stainless hardware and three tabs to weld to the axle and body. On top of that they had the Mopar rear axle Tee I wanted.
https://static1.pt-content.com/images/noimg.gif

After Inline Tube I ran over to Mancini Racing to purchase a new vent tube. Lucky for me they also had a Wilwood Proportioning Valve hanging on the wall for $41. I'll take that!
https://static1.pt-content.com/images/noimg.gif

While at Mancini Racing I saw a product called Lizard Skin. I'm going to contact the company and see about getting a small sample of each just to see what it looks like in person.
http://www.lizardskin.com

Riddler

[Riddler]

Well today I got done with my mock up on some hood struts and it worked, but at the same time didn't work out. To hide the struts inside the fenders you'd need crazy struts with a ton of PSI. I tried to use a pair 90psi struts and while it holds the bare hood open it won't assist bring it up. These struts were nearly impossible to install and the only way I was able to do it was to get them in a 10,000lbs tow strap and tighten them closed. Anyway onto some pictures.

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

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

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

Anyway my plan now is to just go back to using the stock hinges with springs. I'll have them blasted and painted with the car. Who knows maybe I'll even get some hood struts later on and attach them to the hood and fender like the OEM's do it now.


I've also made a new purchase. A set of 1976 Ontario Vintage Plates. I'm hoping I can use them.
https://static1.pt-content.com/images/noimg.gif

Riddler

[Riddler]

Here's a couple of pictures of how I have them struts set up now. Where there at now will help to lift the hood and they hold the hood open at almost any angle. When the hood is fully open the struts can keep it open in a decent wind.

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

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

Riddler

[Riddler]

Well on Saturday, Jim and I made some more progress on the car and finished off the minitubs. The work completed looks amazing and to think we did this with a mig welder and angle grinders is amazing. Just imagine if we had the right tools...

Please bear in mind the heat was killer, 90 degree's with extreme humidity.

These pictures show the first tub completed and tacked in. Afterwards Jim went back and completed stitch welds for strength.
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This is the second side. Here you can see the patch panels I made out of sheet metal.
https://static1.pt-content.com/images/noimg.gif

Through the taillight views, driver's side then passenger. While I was going to be seam sealing the tubs I fixed the trunk extension on the passenger side and got it ready for new seal seal.
https://static1.pt-content.com/images/noimg.gif
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Inside the car view. As you can see I still need to replace the seatbelt mounts. Any idea if replacement seatbelt mounts are available?
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The cross braces for the back seat welded back in.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Now to finally finish the minitubs off, we need to put some better welds on the bottom of the cross braces, replace the seatbelt mounts, and cut the trunk arm braces and reweld them on.

Riddler

[Riddler]

Well I'm now upto date with this build on pro-touring. I've changed one aspect of the car. I've purchased a T56 from a 95 Viper for the build.

So what's everyone think?

Riddler

[dropit69]

very cool build...welcome to the Forum

[r.a.w.rods]

Looking good, you make me want to go out and work on my 70 Duster :)

[wellis77]

It was nice getting a recap on all that Riddler. Thanks for posting that here.

[Riddler]

NP Will. I picked up a Viper trans the last day or so. It's a 95. From my research it's one of the better trans as it can hold 550 torque.

Riddler

[wellis77]

Nice! Moving right along.

[MTMouse]

Nice to see the whole project...all I've seen for the past few months is the back end while driving by.

Your neighbour.

[craigs73]

nice work you guys are doing and no problem posting all those updates at once we like updates and pics :) got to ask tho what the story with your sig? ur brother building duster too?....... guess i have to go to the site :)

[Riddler]

I don't have any biological brothers but a really good friend. We call each other brothers. I live in Canada and he lives in Michigan. He hasn't picked up a car yet but he's been looking. Picky I guess. Eventually he'll find one.

MTMouse, if your in my area you should stop by sometime when the garage door is open and say hello. I'm going to assume your in Belle River? I'd also love to check out your car.

Riddler

[MTMouse]

MTMouse, if your in my area you should stop by sometime when the garage door is open and say hello. I'm going to assume your in Belle River? I'd also love to check out your car.

Riddler

I'm about four doors south of you (house with hockey puck shooting gallery in drive). The cars had to go with the first wife, so now I live vicariously through these forums. I have one more hockey season to get through and then in a couple years my ex will be off my payroll so I hope to get back in it again then.

[irregal83]

Car looks Great! look forward to progress

[Riddler]

Very kewl. Your welcome to stop in anytime the garage door is open.

Riddler

[craigs73]

cool theres one down here by me was for sale by road no its back by garage i dont know if they sold it or what i stoped and looked in needs quarters and floor pans i think it was around $1800

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

[Riddler]

Well I haven't done alot fo work but I did get some stuff done on the weekend.

I seam sealed most of the tubs on the inside of the car. Still have to do the outside and inner wheel wells.
https://static1.pt-content.com/images/noimg.gif

I then put down a good layer of POR15. I'm not even sure I'm going to keep the spare tire area as I might go with a fuel tank that drops in through the trunk.

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

I've still got to do the inner quaters with POR15. I also have a few holes to weld up as well as tack the trunk hinge braces back to the tubs.

Riddler

[FoxGranadaChuck]

Cool build. I just hope that you are modifying the floorpan and the trans crossmember for either the Challenger automatic trans or the T-56 while you are doing the floorwork. ;)

[irregal83]

Nice job on the tubs. how do you like the POR15?

[kmdracer]

Great to see the progress. Keep the updates rolling.

[Riddler]

The front floor isn't done and the center hump hasn't been put back in. The plan is to pay off some of the parts I've just bought and then get a bellhousing and mock up the drivetrain.

I really like POR15 but I'm going to cover it with carpet or NVH stuff. My plan is to make the car sqeek and rattle free as I can. I should be able to get some more updates done soon.

Riddler

[68400BIRD]

Cool build. I can't beleive all the work you got done on the 17th. LOL Keep the pictures and updates coming.

[Riddler]

Well I finally got my butt out into the garage today. I decided since I was dead broke from buying the T56 Viper transmission I would do some of the crappy time consuming work that needs to be done but no one likes to do.

I welded for the first time today. My welder has been busy during the race season as well as with work/family obligations. The picture shows you why I shouldn't weld. :)
https://static1.pt-content.com/images/noimg.gif

Doesn't really matter though since I grinded it down smooth and applied seam sealer over the welds. What your seeing is the trunk lid hinge brackets re-attached to the tubs.
https://static1.pt-content.com/images/noimg.gif

Then I moved on with the tube of seam sealer and did inside the tub where the wheels are. I'm planning to paint this area over with POR15 and then spray a rubberized gravel guard in there to protect the metal and help with some noise reduction.

https://static1.pt-content.com/images/noimg.gif
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Once all this is completed and I can purchase a Quicktime Bellhousing and T56 transmission mount I'll be mocking an engine/trans in and fabricating a center hump.

Riddler

[axisg]

I seen what you did with the Neon over the years and it was exceptional so I am expecting some real quality work on the Duster !

[Riddler]

Well on Friday I found some time as my wife and son went shopping. I decided to try and complete the minitubs and get them squared away.

Here I show you what Ihave left. The old seatbelt mount was rotted away and I needed a new seatbelt anchor.
https://static1.pt-content.com/images/noimg.gif

Here I show you how bad my welding it. While I penetrate the metal, I don't have a nice clean weld.
https://static1.pt-content.com/images/noimg.gif

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

Now with the metal replaced I grinded the welds down flat and seam sealed over it all.
https://static1.pt-content.com/images/noimg.gif

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

After all that dried I painted POR15 over everything to protect it. I did the entire trunk, the rear seat area and the inside tubs.
https://static1.pt-content.com/images/noimg.gif
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My plan is to put sound deadner on the inside of the car and then use rocker guard inside the tubs to cover the POR15 as it has no UV protection. Don't want the sun breaking it down.

Riddler

[FRENCHBLUE72]

I have always loved the dusters I dont know im a chevy guy but I guess even mopars could find there way into my shop at some point... Your car is really comming along keep up the good work..

[Riddler]

Well it's been a while, for a few reasons. Saving money to buy parts, renovations on the house (new office) and an active 6 month old baby boy. :) I've recieved my 8073 Quicktime bellhousing a few weeks back.

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

The bellhousing did not come with instructions, lucky for my I've located some info about replacing the cheap bolts from quicktime with Grade 8 bolts. I bolted on the bellhousing to the trans.
https://static1.pt-content.com/images/noimg.gif

As you can see only seven bolts are required as this one bolt near the starter opening doesn't line up.
https://static1.pt-content.com/images/noimg.gif

Here's a couple of pictures of the bolts. Silver are cheap grade 5 and the gold are grade 8.
https://static1.pt-content.com/images/noimg.gif
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Then since I had the Hurst Billet Pro shifter I bolted that as well.
https://static1.pt-content.com/images/noimg.gif
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Well hopefully next time I'll have the mock up 5.7 block and T56 in the car and working on getting the floor finished.

Riddler

[FRENCHBLUE72]

New parts are always nice congrats on the new addtion to the family..

[ALLstrokedOUT]

Ive been watching this one for a bit now, love everything youve done/ are doing! Be careful when you go to install the throw out bearing that theres enough clearance between the hydraulic line and the scatter shield. I had to clearance mine for the 4AN adapter fitting to fit rite ( I learned after i broke a fitting off and had to drop the trans to replace the fitting at the throw out bearing...)

[Riddler]

You have some pictures of how you clearanced yours? I'm not 100% sure what you mean. I'm hoping to mock up the block and trans soon so I can finish the floor.

Riddler

[ALLstrokedOUT]

Sorry, not the best pictures but heres what was happening, th braided line should be straight:
https://static1.pt-content.com/images/pt/2011/06/DSC01366-1.jpg
Which caused this to happen to my clutch to -AN adapter nipple:
https://static1.pt-content.com/images/pt/2011/06/DSC01369-1.jpg
Sloppy grinding with a bur to resolve the issue:
https://static1.pt-content.com/images/pt/2011/06/DSC01371-1.jpg

[Riddler]

So I had some time today and I really want to get the mock up hemi block and T56 into the car so I can finish the floor. Once the floor is done I can finish painting POR15 and then save to have the body work done.

Pictures were taken with iPhone instead of DSL.

Here's the block on the stand and engine picker getting ready to put into the car.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Here's the hemi block in the car with the mounts figured out. Small one on the passenger side, large on the driver's.
https://static1.pt-content.com/images/noimg.gif

Then I bolted on the block plate to the bellhousing. Not all bolts used for mockup.
https://static1.pt-content.com/images/noimg.gif

Last but not least I mated the Hemi block to the T56 trans. The trans slid on the dowels and the bolts fell into the holes. Was super easy.
https://static1.pt-content.com/images/noimg.gif


I was unable to get the block and trans into the car myself. I'll have to wait until I can get some help. Hopefully I'll have updates quicker soon...

Riddler

[Riddler]

I found some more time today and decided to muscle the engine/trans into the car. I'm hoping with it in there I can finally finish the transmission crossmember, floor and some other minor welding. Here's a few pics of the trans where they floor should be.

https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif
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I'm thinking I might have a local fab shop make me a nice tunnel for over the transmission. I'll have to see what can be done without taking my car anywhere.

Here's the engine bay with the engine/trans in.

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


Riddler

[FRENCHBLUE72]

How about building the trans cover out of cardboard and then getting a shop to build you what you want??

[Riddler]

How about building the trans cover out of cardboard and then getting a shop to build you what you want??

This is the plan. I'm going to get the crossmember done first so I don't have a jackstand holding up the trans.

Riddler

[ryeguy2006a]

That is looking great. I was just looking at the quicktime bell for my Pontiac. So would you say overall that you were happy with the quicktime?

[Riddler]

Yeah the quicktime bell bolted up and everything lined up great for me.

Riddler

[Riddler]

Well I haven't had much time to work on the car with life happening. My welder (brother in law, officially now) went and got married and we had his reception, my wife broke her foot and it's healed and I'm currently getting over a nasty flu with my 9 month old son. So there have been better days....

I may not have been working on the car but I have had my fuel tank designed and is currently being built by Tincup and White Trash (members on http://www.forabodiesonly.org). Here's the design.

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

The plan is to have the tank drop in through the trunk. The top will remain flat and the pump/fuel level sender will be hidden under a small acess panel. The lines will run out under the car and won't be inside the trunk.

Here's some pics that have been sent my way by the builder.

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

I've got some more surprised to let out of the bag soon.

Riddler

[Riddler]

First I want to show off my welder. It's setup for flux core right now until I can afford to pony up for a bottle of argon.
https://static1.pt-content.com/images/noimg.gif

Now onto the new parts. I loved the new fender/front rad support covers Ross made and he offered to send me a pair. Thank you Ross. These are going to work out great!
https://static1.pt-content.com/images/noimg.gif


Finally my fuel tank has been finished and shipped to me. Micheal and Eric did an amazing job on this tank. It's perfect! The welds are clean and the extra's I asked for were spot on. I'll let the pictures do the talking.

FYI - shipping folded over the covers slightly, nothing I can't straighten though.

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

Here's the filler tube with vent.
https://static1.pt-content.com/images/noimg.gif

Here's the access panel.
https://static1.pt-content.com/images/noimg.gif

What's under the access panel?
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif


Well I'm super excited to cut the trunk floor out and get this tank installed. But I know I need to practise welding before I weld in 1" strips of metal to help strengthen the floor.

Riddler

[Riddler]

It's been a while since I've posted but I've been working on the car here and there with small updates and purchases. I've been working on the Peaks Dashes and working on getting it to fit perfect. Takes alot of time.

Today I found time this afternoon to cut the trunk floor out my car and install the fuel tank.

Here's the marking lines.
https://static1.pt-content.com/images/noimg.gif

Here's the trunk floor cut out.
https://static1.pt-content.com/images/noimg.gif

Finally the fuel tank installed in the car. I just have to get some sheet metal screws or nuts and bolts. I'm leaning towards nuts and bolts.
https://static1.pt-content.com/images/noimg.gif

Here's the view through the filler door opening to the tank. Looks like a good fit.
https://static1.pt-content.com/images/noimg.gif


More updates soon, I hope. :)

Riddler

[Riddler]

Well I've been getting the fuel tank ready more and more for a better fit. The floor needed two small patches made and welded in. I welded a small piece where the fuel gasket is and also a 1.5" strip down the back right up to the back panel. I've not got it seemed sealed and I'll POR15 it tomorrow.

I've decided I want to be able to take the tank out in the future so I chose to install threaded inserts to hold the tank down. 1/4" -20 aluminum inserts worked great. I've not got the stainless hardware to go with the tank as well.

The tank itself got a strip of self adhesive body tape all around it to prevent rattles and smoke coming into the trunk during burnouts. :)

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

I've been working on the transmission crossmember as well with my neighbor and should be done soon. Once thats done I can finish the floor and the inside POR15.

Riddler

[Riddler]

Well I had the entire morning to work today. Wife and baby chose to sleep through the 100* weather all morning.

I just finished up the fuel tank mounting. I took better pictures of what I've done as well as painted the POR15 up around the rest of the body work.

Here's the tank with the seal mounted.
https://static1.pt-content.com/images/noimg.gif

Here's the before POR15 pictures.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

And now the after pictures of it all painted and proteted.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif


I then moved on the the Peaks Dash I have. I've been working it and massaging it to fit for weeks on and off. Today I took drastic measures. I cut the glove box door up and made it fit the way it's suppose to.

Just a picture showing the glove box cover not really lining up and you can see what I've done to help that.
https://static1.pt-content.com/images/noimg.gif

I chose to get rid of the half round as it wasn't in the right place and the knob just didn't fit it right. Glad I kept the stock plastic trim peice for the glove box door.
https://static1.pt-content.com/images/noimg.gif

The glove box massaged and ready to install. It took hours to get it to this point.
https://static1.pt-content.com/images/noimg.gif

Here are some fitment pictures of the gauge area.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Last but not least the final pictures. The glove box lines up with a 1/8" gap between the door and main dash and the bend in the dash finally lines up when you see it.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Here's the close up view of the glove box door.
https://static1.pt-content.com/images/noimg.gif

I'm sure I'll have do play with it some more but for now I'm very happy with how it's come out. My future plan is to grind the heads of the screws down and fiberglass over them along with the bottom edge so it looks like one piece.

Riddler

[Riddler]

Well another day, more work completed. I wasn't able to weld much the last few weeks as I needed a welding extension cord. I was going to make my own but a local store had one go on sale for 50% off. So I snatched it up.

So I'll start off with the hydroboost unit I obtained from a local wrecking yard. Not a bad score, looked fairly new, was clean and the vehicle it was on had the steering column removed. I cleaned it up and gave it a coat of gloss black and high temp clear.

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

All done with clear...
https://static1.pt-content.com/images/noimg.gif

I then took my time to make a template to take to the laser cutter.
https://static1.pt-content.com/images/noimg.gif


i then moved on the transmission crossmember. So far I've gotten it all mocked up and tack welded. Today I finally was happy enough to weld everything up. The picture shows the final welds I put on the ends and transmission mount. I'll clean those up some and prolly just primer it. It'll prolly be sent out to be powdercoated with the other parts.

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


Then finally between the coats of paint drying and the welds to cooling down I got to playing with the gas struts from the hood. I didn't like the way they didn't open the hood only kept it open at certain angles. So I used them on the trunk and with two 90lbs struts the trunk goes up and down with ease!

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

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

Finally a video my wife helped me take of the trunk lid opening. Just need to find an electric trunk release now.

http://www.youtube.com/watch?v=424hdgJIF5s&feature=plcp

Riddler

[Riddler]

I picked this up yesterday from a local guy for $150. 1" bore Wilwood master cylinder. Perfect for the hydroboost install.

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


Now that I have this thread updated again I promise to keep up with it more. LOL

Riddler

[Riddler]

I painted the crossmember and bolted it up tonight. I then started tackling the floor and grew frustrated and walked away.

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

I was going to make a cross brace over the top of the trans out of 1/2" bar stock and combine 2 of those with some 1/8"x2" steel flat stock. But I think I might go out and try and find some 2"x1/2"x1/8" U channel.

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

Riddler

[MTMouse]

I saw the door open on the weekend, but didn't see any movement when I went by a couple times.

I will stop by sometime with my 16 year old son. He has taken an interest in cars and keeps bugging me to pick up a project. If I had all the money I put into his hockey over the years and didn't have to pay the first wife, I could have bought a couple of Stielow's cars. :)

[SparkyRnD]

this is an incredibly cool build, and I can't wait to see it as it gets closer to being done

[Riddler]

I found some time today to get some work done. My goal was to button up the floor. I gave it my best but I failed. I did have a good start and wish some cardboard I can make templates and finally finish the floor.

Here's the bridge over the trans I made. It's 2"x1" C channel and has 1/8" plates to weld to the sheet metal floor.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

I've finished welding it up but never got a picture. I also clearenced a few sections so that I've 1/4" or more of space from the trans to the bridge.

I then moved on to messing with the pedals and hydroboost. I took all the brackets off the pedals I didn't need. Anyone looking for heavy duty 340 brackets etc?
https://static1.pt-content.com/images/noimg.gif

Here's what I was left with.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

I then mounted up the hydroboost. The brackets were perfectly to the firewall. Just have to take a hammer and smack a buldge down about 1/4". I then however stuck a hemi head on the driver's side and found that the hydroboost won't allow for the room needed to mount the valve covers.
https://static1.pt-content.com/images/noimg.gif

I'm going to run to the laser cutters this week or early next week and see about getting another brackets cut for clock the hydroboost counter clockwise 90*. This will allow me the extra space I want to have to install and remove the valve covers. I'm also going to have to have a bracket made to clock the master back 90* in the other direction so it mounts flush.

Riddler

[Riddler]

Well I was able to get to the laser cutter to get my new improved 3rd gen hemi hydroboost brackets. This setup requires a 3/8" spacer plate and a 90* master cylinder bracket (1/8") on top of a new hydroboost bracket with the notch on the bottom to clock the hydroboost. I'm hoping to get some mockup pictures soon.

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

I'm sort of working on two ends of the car at once. I'm working on getting the trunk wrapped up as well as the body. For the truck I bought an electric trunk release. I'm not 100% sure how it works yet but I do plan on bench testing and hopefully playing with it in the car.

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

I then moved on to finally getting the floor completed. I've still got about half more to do but the main portion of the tunnel is completed. Just want to say that the T56 trans is HUGE!

First I spent time making a template till I was 100% happy with it.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

I then moved on to tracing the template to 16 gauge sheet metal.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Finally I burned the sheet metal template into position. I'm still planning to clean the welds. I'm also planning to remove the engine and trans and complete the tunnel on the underside.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif


While I realize this might not be the way you would of done it, this is the way I chose to and it works for what I have in mind. Now to mock up the rear panel and a small sliver of metal for the passenger floor board and the floor should be done.

Riddler

[Tincup]

Coming along nicely Riddler.......

[MTMouse]

I just picked up a project for the son and I to work on... so hopefully we can trade labour over the winter. ;)

[Riddler]

MTMouse, I just saw the beast in the driveway! VERY NICE!

You need to get a project long started so I can post in it. I'm in the garage all day today finishing up the floor and other small projects before I start the next few.

Riddler

[Riddler]

Well I'm super happy to annouce the floor is completly solid once again. I'd got to get some more seam seal and then lay that down and some POR15 inside and under the car the new tunnel is done.

This was a much bigger job than I expected and much larger than the mini-tub anyday!

Here's the final pics.

You can see small holes here from rust. I cut that out and replaced it.
https://static1.pt-content.com/images/noimg.gif

Banged all the metal flat again the new floor, welded it and then used clamping plyers to hold the seams together while I welded them shut.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Here's the hole I made and replaced with new metal. This was super thin and I couldn't get the welder low enough to weld the holes shut without making more holes.
https://static1.pt-content.com/images/noimg.gif

The final look before seam seal, POR15 and then sound deadener.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

So the next things I'm going to work on are:

Shorten Steering Column
Fit hydroboost
Make base for the drive by wire gas pedal
Extend the fuel filler neck.

Riddler

[Riddler]

So believe it or not I found some time today to work on the car. While I didn't get a ton done I have actually touched the car for the first time in 6 weeks. Work and family life have been time consuming.

First thing I did was fabricate a gas pedal mount. I wanted something a little stronger to weld to the floor other than just nut and bolting the pedal to the sheet metal.

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

This gas pedal is an LX hemi gas pedal. If anyone wants one of the mounts just ask, I can have more cut. Tapping the holes and welding studs in will be an extra cost.

While my drill was charging I decided to finally finish painting the floor with POR15. I now know I'm goint to have to purchase some more POR15 as my gallon is almost gone. I'm guessing I can finish with a quart...

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

Well I'll keep working on the car over the winter and hopefully be ready for paint by the spring... Let's hope I can afford it.

Riddler

[HawkeyeGT]

Youve come a long way, and its looking good. Keep it up!

[MTMouse]

Looking good. Figures, you get the nice warm days on your day off...should be nice and cold on my days off. :(

[im4u2nvss]

Nice work! I have enjoyed checkin it out.

[LeighP]

Very cool build...just read it all from the start. Nice work!

[Riddler]

Thanks guys for the comments. I'm trying hard to get time to work on the car, although I do have an 18 month old.

Yeah MTMouse it was really nice. I don't have heat in the garage yet but I'll soon find something to kill the chill. I noticed no new pictures of your car have been added lately....

Riddlet

[Motorcitydak]

When you paint everything with POR, do you do the whole 3 step process of the marine clean, etching then paint? I am planning to do a lot on my interior pieces like that too

[LeighP]

I painted out the trunk in my 70 RS/SS Camaro with POR15. Followed the "marine Clean", then "Metal Prep" (basically rust converter), then cleaned it again with water to remove any metal prep excess...warmed it up to make sure it was dry, then painted it with the POR. The stuff covers really well, small amount goes a long way. When it was done and dry, I had a glossy, extremely hard trunk floor that never looked like chipping.
Good stuff, when used correctly......works best on seasoned metal, rather than bright new stuff, unless you key the surface.

[Riddler]

I've just painted the POR15 right over bare metal, primer. I just blow the panels clean of dust and debree. The stuff is like an epoxy, once on there, it don't come off. That goes for the clothes, skin, floor, painted parts, tools everything. So be sure to wear gloves and protection. If it gets on your clothes, it seeps through.

Riddler

[linkstar69]

Cool build.

[Riddler]

Well I'm mostly done welding up the metal around the engine bay. Enough that I could remove the front and rear suspension parts and take them to my new sponsor JP Coatings (www.jpcoatings.com) in Monroe, MI. Jeff know's his coating and can even do ceramic. If you want the number to JP Coating it's on his site or PM me.

Now onto the pictures..

Here are some of the parts stripped down to bear metal.

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

Now onto the coated pictures. I did the RMS K frame and my custom T56 crossbrace in Chrome powdercoat.
https://static1.pt-content.com/images/noimg.gif

The rest of my parts were done in Tiger Anthracite. Beautiful color!
https://static1.pt-content.com/images/noimg.gif

These covers were from an 03 Hemi and were heavy pitted. Came out pretty good for not really doing anything other than blasting.
https://static1.pt-content.com/images/noimg.gif

Here are the 2 colours next to each other.

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

I can't wait to go back and have more done.

Riddler

[Riddler]

Well I forgot I was posting here. You've all missed about 2 years worth of work. I'm going to update tonight.

Well I ended up finding about two and half hours to work on the car today. I ended up using the first 30 minutes to clean up since it's been a at least a month since I've done really anything.

I decided I wanted more room for the hemi underhood and I "borrowed" tincup's inner fender mod idea.

Here's the before...

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

As you can see everything outlined in black I'm planned to remove and weld flat panels in. I'm also going to remove everything from the firewall that's no longer needed.

Here's where I started...

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

Well I guess it's time to put some metal back.

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

As you can see I cut it really low giving me the maximum amount of room for the big ole Hemi underhood. :)

Here's how I'm going to solve the hole required for the alterKtion.
https://static1.pt-content.com/images/noimg.gif

Once it's all welded in I'll break out the short hair fiberglass and make it look perfect.

Riddler

[Riddler]

I found some more time today as my wife took our son for dinner with friends. I started by burning in the plates for the chassis stiffening bars I made.

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

I then went ahead and filled all the holes in the inner fender. I'm planning to make it nice and smooth. Fiberglass with assist in that.

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

Afterwards I grinded down all the welds and made them look much better. It's ready for fiberglass and primer. The little bump is to help cover the top of the alterktion crossmember as I cut the panel too low. Now to match up the other side.

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

Finally took some time to fit the bar and burn it in. I can see how these stiffen up the car.

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

My plan is to seam seal this side and get it ready for POR15 or rocker guard. Haven't decided which one.

As soon as I find more time I'll get the driver's side done.

Riddler

[Riddler]

So I finally found some time to do an update. Most of what I'm showing you is from the last two weeks. After I had all the suspension powdercoated by Jeff's Powder Coating in Monroe, MI, I had to clean every thread. This is slow and tedious work....

Everything went well uptill I started threading in the heim joints into the upper control arms. The driver's arm had some media dust in it and while threading the heim joint in I managed to gall the threads. After about five hours of cursing and heating the part, the heim joint locked up and not even two grow men hanging off a pipe could loosen it. We did manage to loosen the vice off my work bench.

Here's the upper control arm. You can see the powdercoating is gone from the torches we used. This part is garbage!
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

I just want to say that Bill at Reilly Motorsports has top notch customer service and sent me out another upper control arm. I'll remember to soak all the heims in anti-seize from now on!

Here's the assembly I have done upto this point.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Now just remember each bolt hole and such had to be cleaned of powder.

Finally I needed a tool to screw in ball joints. This is what I had made by my laser cutter. I figured a nice 1/4" piece of steel would be better than the aluminum ones that another company sells.

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

Riddler

[Riddler]

Well here the info and pictures I missed from the last update. Goes to show I've actually done more work than whats posted.

I posted a while back that I bought the Duster specific Corbeau seat brackets. I was hoping that they would just bot in but that's never the case.

Here are the seat brackets and as you can see they don't fit my 1976 Duster floor that has the area for the cat converter. First is the driver's side and you can see the tabs don't line up with the holes and the bracket is at about a 30* angle. Passenger side is about the same. One hole doesn't line up and the main bracket interfers with the floor.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Instead of cutting the floor out I chose to modify the brackets which was really simple. The white lines you see is where the brackets interfer with the floor. You can also see the tabs I had to cut off and reweld.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Now the last things to to do with the seat brackets is to get them re-powder coated and bolt them in. Once that's done I'll tack weld the nuts on under the car so its easier to install the seats.

Here are the rest of the engine bay pics. I've completed the Tincup mod for the strut towers and makes for a ton of room.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Here's the engine bay as it sits.
https://static1.pt-content.com/images/noimg.gif

I'm saving up for my evaporator box from Vintage Air and then I plan to smooth out the firewall and relocate the wiper motor. A smooth firewall is sexy!

Riddler

[Riddler]

I spent some more time this weekend at the powdercoaters. I have to say I love this place.

This time I went over as he needed a smal hand around the shop. I took with me my seat brackets and wiper linkage.

Here's the pictures of that stuff. Before
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

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


So today after work I decided I wanted to put the seats in. So in they went. Needed to trim only two plates where the holes were.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Riddler

[Riddler]

Well here's an update. I've done nothing on the car as life has kicked me in the butt. Working full time, a 2 year old (can you believe he's 2?) and having a pool installed have all led me to have no time to get anything done.

But why am I updating? Well I won an eBay auction last week close to home for a new power plant. But what about the 5.7L Hemi he was going to install? Well I'm selling all the 5.7L Hemi parts.

Here's the new power train ready to be installed. I just need a few things here and there. I'll get to that in a minute...
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Just in case your a not upto date on these engines...
https://static1.pt-content.com/images/noimg.gif

So to update it a bit more I've been doing research into what oil pan and headers I need for this engine.

Riddler

[Riddler]

Well I'm trying to compete the metal work up so I can move on to mocking up the pedals, brakes, etc etc

The Duster firewall isn't smooth in a least bit, but that doesn't bother me. However I did have to cut the stock AC area out as I needed this area flat for the Vintage Air evaporator to sit against the firewall.

I marked the lines and cut it out.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

You can also see in the above picture the gas pedal area needed to cut a little. I needed the gas pedal to sit angled more towards the floor for driver comfort. Now I just need to weld that all shut again.

Then using a cardboard template I marked the steel for cutting.
https://static1.pt-content.com/images/noimg.gif

After all that I welded it in. You can also see the AC bulkhead I welded in. I had to place it a small angle as the Hemi needs the room for valve cover removal.
https://static1.pt-content.com/images/noimg.gif

I have the wiper area cut and removed as well. The next time I need to weld in a flat panel and all the useless holes.

Riddler

[Riddler]

Well back to work today...

My goal is to get the firwall as straight and smooth as possible. I've only got a few more holes to weld up, then a ton grinding and then fiberglass to smooth it.

Today involved welding the gas pedal mount solid. I've still have to make a plate for that area to make it look like the firewall is smooth. I then moved on towards the wiper motor area. I've cut it out and plans are to use a modern motor with a delay function. I snagged one out of a Dakota to use.

Wiper area cut out.
https://static1.pt-content.com/images/noimg.gif

Plate made and welded in.
https://static1.pt-content.com/images/noimg.gif

I also made a new top piece and made it look as factory as I can.
https://static1.pt-content.com/images/noimg.gif

Grinded it down smooth and it's ready for a thin application of short hair fiberglass.
https://static1.pt-content.com/images/noimg.gif

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


That's all for today.

Riddler

[Riddler]

Spent most of the day in the garage working on the car. Today I wanted to start getting the firewall mocked up with the hydroboost and clutch master. So lets start with those.

Here's the hydroboost mockup.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

I still need a few things to bolt the rod to the pedal. I'm gonna have to buy a 3/8" heim joint and then cut the stock loop off and tap the rod.

I then spent 4-5 hours mocking up the clutch master.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Here's what I've got going on under the dash (not done)
https://static1.pt-content.com/images/noimg.gif

I then dropped in the steering column to see how it looked. Well once that was in I could tell the driver's seat was about 2-2.5" too far to the left. So I moved it over 2" and its much better now. No I have to make the bracket fit again with new mounting tabs and then get it powercoated once again. Opps!

Riddler

[Riddler]

Well I haven't been under a rock, just spending more time with family and enjoying my son growing up.

I have however been buying parts and I'm planning to get a whole lot done this coming year.

Here's what I bought so far.

Milodon Oilpan, pickup, OEM Bolts. Still not decided on the windage tray and gaskets or an OEM gasket/windage tray.
https://static1.pt-content.com/images/noimg.gif

Here's the Lokar Parking brake. I've got everything needed to install these so the car can be put out on my driveway without it rolling away.
https://static1.pt-content.com/images/noimg.gif


I'm hoping to have some more progress soon. I guess it depends on the weather and how cold it's been.

Riddler

[Riddler]

Well I spent the better part of today outside in the garage. Since I haven't been out there in a few months I needed to clean up. That took a few hours.

I did get something's done on the car though.

I welded in the shifter surround and made it look more factory.
https://static1.pt-content.com/images/noimg.gif

I then mocked up the e-brake bracket and tack welded it in place. I have to get the seats in again to check and see if I like it there.
https://static1.pt-content.com/images/noimg.gif

Here's both together.
https://static1.pt-content.com/images/noimg.gif

Finally I started getting the wiper mocked up inside the car. I'm using a 2002 Neon motor with a modified main wiper arm. I just need to finish the final weld of the bracket to the wall.

Here's a video:
https://www.youtube.com/watch?v=X4jVt3GyaP0" onclick="window.open(this.href);return false;

I'm planning to get back to work on this more regularly this summer.

Thanks,

Riddler

[Riddler]

Well I've been strumming along quietly working on the car. I'm hoping to send it off for body work and paint soon.

I've finally finished the inside firewall and floor. I'll have a body man finish up the engine bay side of the firewall.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

I also finished giving the underside a good healthy coat of rubber undercoating.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

I then started hanging the doors. The driver's door is on but I think I need to shim it out the top of it. I'm also in need of a handful of bolts for the passenger door.

I'll be finishing up some more and hopefully sending the car off to paint soon.

Riddler

[Riddler]

Here's the newest update. I know it's been a while but I haven't done much other than buy parts and check out paint shops. The car left a couple of weeks ago as I found a small custom hot rod shop that I really liked. They really only do old muscle and custom paint jobs. In fact they just finished a 67-68 Cuda in order to get the Duster in.

Also in the shop is a 67 Charger with a 5.7L hemi swap. I'll get pics of that next time.

Here's what's going on now.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif
They didn't like my small patch panels and we agreed on cutting the firewall out and welding in a full size patch.

https://static1.pt-content.com/images/noimg.gif
Just some minor body work. The original lead was left but a quick skim of mud over it to seal it and get it ready for tons of block sanding.

https://static1.pt-content.com/images/noimg.gif
The driver's side fender was way too banged up. The door at one point was out of align and just crushed the fender. This one came from California and is getting chemical stripped and cleaned up.

https://static1.pt-content.com/images/noimg.gif
Finally this is how the car looks during body work.

I've also now purchased the entire fuel system and brake system. When the car comes back from the paint shop with the engine bay and jabs painted I'll install everything needed to get the car running and stopping and then the final paint will be sprayed.

I'm looking at Gunmetal colours but haven't picked one out of the rest yet.

Riddler

[Riddler]

Here's the newest update from the shop. The car's had a little more work done and I took some pics just to keep myself up to date.

Here's the passenger side fender with one of the corner covers Ross sent me. This is going to make it look much cleaner under the hood. I bought billet hood bumpers from Fesler Engineering to clean it up just a little more.
https://static1.pt-content.com/images/noimg.gif

The engine bay is getting a total smooth look. It took a little more putty than I wanted but I was told this still needs many hours of block sanding down.
https://static1.pt-content.com/images/noimg.gif

Here you can see where I cut and welded the frame rail back for the alternator on the 6.1L Hemi.
https://static1.pt-content.com/images/noimg.gif

The smooth firewall is looking much better. The shop cut everything I did out as they said it would of needed too much bondo. Here's the final look now...
https://static1.pt-content.com/images/noimg.gif

The last two pictures are of the passenger side which is much further along than the driver's side. I pointed out a few spots and the shop is taking car of it.
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https://static1.pt-content.com/images/noimg.gif

My little guy photobombed the last pic. He's just as excited as I am.

Riddler

[Riddler]

Second update in one day? Can it be? While the car is off getting body work and paint I've been busy with small parts here and there.

Here's how the T56 transmission sits waiting to be mated to the 6.1L Hemi.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

I cleaned it up and sanded it down. Took about 4 hours total for that and another hour for painting. I made sure to tape everything off. Installed all new seals and parts while I was at it.

Riddler

[Riddler]

Here's the newest update. The car should be back sometime in November with the engine bay, door jams and under the trunk lid painted. Might be difficult as I haven't chose a color yet.

Here's where the car is at...under the hood getting nice and smooth.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Passenger side of the car is ready for primer which was shot after I left.
https://static1.pt-content.com/images/noimg.gif
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Driver's side is being worked on now. The door has been an issue to get lined up.
https://static1.pt-content.com/images/noimg.gif

I've also taken the dash with the Peaks Dash insert in and they panel bonded the aluminum insert to the steel dash frame. I then asked them to fiberglass the dash so it looks like one piece. I'm going to color match below the dash pad to the outside color and from the dash pad to the windshield will be flat black.
https://static1.pt-content.com/images/noimg.gif


Riddler

[Riddler]

Well it's been five long years but Project EH-body has some colour on it now.

Here's yesterday's pics from the painter.
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Today I was sent these pics.
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https://static1.pt-content.com/images/noimg.gif


I should be getting the car back next week with all the jams and engine bay complete. Then I'm suppose to install the drivetrain and brakes so it runs and stops and the shop gets it back again for final block sanding and paint. I'm hoping to have the car for about 6-9 months to get the drivetrain in and brakes done. Still need to buy all the wiring and such and with this being a cash build.....

Riddler

[Riddler]

Here's the next round of pics sent by the painter this weekend.

First off a couple to show assembly of the doors, trunk and hood.
https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/noimg.gif

Next up is what the inside of the fenders look like...
https://static1.pt-content.com/images/noimg.gif

Finally I've been having a hard time choosing how to do the hood. Full flat black, just the scoop flat black or paint it all body colour. Still can't decide. What do you think and why?
https://static1.pt-content.com/images/noimg.gif

Thanks,

Riddler

[Riddler]

Here's the latest update. The deep freeze halted into high 30 degree weather. I built a cart for the engine trans and unbolted the K frame. Plan is to get the engine/trans mounted to the kframe and drop the car down over top so I don't damage the painted engine bay.

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

Odd angle of the cart under the car
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Picture of the car sitting on the crate.
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Kframe sitting on the engine stand waiting for the Hemi.
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Finally here's a picture of the color I chose with some chrome next to it.
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That's it for now....

Riddler

[Riddler]

Here's a huge update. I've done little things here and there but this is a large update.

The best to install a motor in an A body is to drop the car on top of it.
https://static1.pt-content.com/images/noimg.gif
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Proud it's finally going into the car.
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Engine and trans is in and bolted down.
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Rack is close to the oil pan but it fits.
https://static1.pt-content.com/images/noimg.gif

Then it was time to put the suspension back on.
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Finally in and suspension on.
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Then it was time to put it back on the ground.
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Finally it was time to put the hood back on...
https://static1.pt-content.com/images/noimg.gif

Here's the only trouble I had with it all. The reverse lockout on the transmission was hitting the floor. Had to cut it out and will prolly have to make a small piece and weld it back in.
https://static1.pt-content.com/images/noimg.gif

Riddler

[Riddler]

Well that's it for now. I've welded up the floor around the reverse lockout and repainted it. I now have some sound deadener from Second Skin and will be applying it when it warms up again. Also now that the motor is in, I'm planning to button the brakes, e-brakes and the rad/fans.

I'll try harder not to miss anymore updates.

Riddler

[linkstar69]

Mammoth effort

[FRENCHBLUE72]

Looks great congrats

[Riddler]

Found some time the last couple of days... not much but I made due.

I finally got the AC and heater box cleaned up mounted and the hoses run for the heater lines.

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

Hoses installed. Just need a pair of claims and another 90* fitting from summit.
https://static1.pt-content.com/images/noimg.gif


Then I got busy with some sound deadener from Second Skin. This stuff is amazing. It's flat black aluminum with butyl rubber. Rolls down easy and stays stuck really well.
https://static1.pt-content.com/images/noimg.gif

Never mind the gas pedal mount.
https://static1.pt-content.com/images/noimg.gif

Half of the ceiling done. Will finish it up next time I'm in the car.
https://static1.pt-content.com/images/noimg.gif

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

Starting to look a lot better. Now if I could find more time and money.
https://static1.pt-content.com/images/noimg.gif

Riddler

[72BBSwinger]

Looks awesome Joe!

[Riddler]

Well Ive been off this site for a few years as I could get logged in and the password reset didn’t work. Somehow today it worked again??? Weird.

Anyway the car is done. Took 10 years to get it going and I’ve still gots things to do. But I’m driving it.

166065
166066

Thanks,

Riddler

[Tincup]

Looks awesome. Better late than never..:firefire:

[68Formula]

Gorgeous! Didn't realize they still made them in 1976, since the Volares came out that same year.

[sefus]

Stinking awesome! I have a 73 swinger thats getting wrapped up after about 15 years of on again off again work and always wanted to turn a duster into a highway cruiser. What seats did you end up with in there?