Modern Bullitt Charger build

[wfo guy]

Cool. Have you counted how many holes you have to fill yet? I think my record is 62. I try to forget the pita stuff.

[keepat]

Cool. Have you counted how many holes you have to fill yet? I think my record is 62. I try to forget the pita stuff.

Wow, hopefully not 62. I think the fire wall has about 25 holes to be filled and I'm sure there are a few more on the inter fender wells. I think I'm getting closer to the bodywork and painting stage of this project, I hope? ;-)
Thanks
Pat

[keepat]

The RMS suspension requires a few holes drill through the frame and they tell you not to over tighten these bolts so you don’t collapse the frame. So I welded in 2 reinforcements to help prevent that from happening. The 1/8” plate is welded on both sides.
Thanks
Pat

[Motown 454]

Nice! That should keep it straight.

[wfo guy]

That was quicker than sleeves.

[langleylad]

Damb , you are one smart fella ! That driveshaft loop/crossmember ...... wow ! . Do you actually sleep at night ? Your brain must be working overtime .

[813Demon340]

Great idea! Love the build.

[keepat]

I started filling all of the unused holes in the engine well and have the left inner fender and core support finished, so far over 50 holes.
Thanks
Pat

[wfo guy]

I was wondering if something had happened to you! I'm guessing 50 is a beginning.
It's all part of it but not my favorite.

[keepat]

I was wondering if something had happened to you! I'm guessing 50 is a beginning.
It's all part of it but not my favorite.

I was out of town working at the Miami boat show, still got pay for this hobby ;-)
Thanks
Pat

[keepat]

I’ve had a few people ask how I remove the paint, clean the metal and finish off the welds, so I thought I do little right up and some pictures on what has worked for me.









In the engine bay I have found a heat gun and wirewheel on a drill works great removing the paint and original primer from all the nooks and crannies. I like using a 12” quick change extension to hold the wire wheels. The advantage of the drill over a grinder is you can change the direction of the drill which allows the wirewheel to work more aggressively remove the paint and primer. With the heat gun I blister about 6”x6” of paint and while it is still hot I use the wirewheel to remove that section of paint, it goes quick and no fine dust.








Here is a before and after of the firewall using only the heat gun and wirewheel.












Here I’m welding over the wire harness plug hole. After tack welding the cover in place I grind down most of the welds before finishing the welding, this helps keep the heat down and make it easier to connect the weld as thickness of the metal is similar to the welds.









I like to use a 90 degree Die grinder with 2” 36 grit disc to take the welds down. Keep it moving and always use new disc when working small areas as worn disc will just heat the metal instead of cutting the weld down. When the welds are mostly cut down you can hammer and dolly the panel flat and then finish off the leftover weld with a 60 grit disc.





Note before hammer and dolly the panel you will need to grind down the weld on the back side!







The last thing I do is use a 6” random orbital sander with a ¾” foam pad and 100 grit paper to clean the metal.
Thanks
Pat

[Dave B]

Awesome! Love your work.

[wfo guy]

Pat, am I correct in thinking you were trying to save some of the original paint rather than blasting the whole car? Firewall is coming along nicely.

[keepat]

Pat, am I correct in thinking you were trying to save some of the original paint rather than blasting the whole car? Firewall is coming along nicely.

All the paint will be coming off, but as this car didn't have much rust I chose not to blast the car only the big parts that came off like the fenders, hood, and doors. Unibody car hold so much media and it is a pain to get it all out.
Thanks
Pat

[keepat]

The paint is removed and all the unused holes are welded up in the engine bay and ready for epoxy primer.
Thanks
Pat

[wfo guy]

I'm reminded again that that is a large car. Some things we count square inches. I'm counting square feet for you.

[keepat]

I'm reminded again that that is a large car. Some things we count square inches. I'm counting square feet for you.

Yes there is a lot of real estate to cover on this car and I haven't even started the real body work yet :-(
Pat

[chunger]

It's a work of art. You should just clear coat that.

[Motown 454]

Wow that's a lot of work done right there! Nice job.

[keepat]

It's a work of art. You should just clear coat that.

clear would be cool but it will be black ;-)
Thanks
Pat

- - - Updated - - -

Wow that's a lot of work done right there! Nice job.

Yes I'm happy it is done!!
Thanks!
Pat