I am right in the beginning stages of doing a resto on a '68 Charger. Specifically, changing alot of rusted sheetmetal. As I am drilling all the spot welds out to remove the original rusted metal to replace with AMD stuff, I started wondering exactly what was the procedure to put the car together?

From start to ending with a complete unibody, does anyone know the steps that the line took to welding all the panels and frame rails together. some spot welds look like they were inaccessible even though they had spot welders with long tongs.

Any old timer that were there on the lines that know?

Thanks for satisfying my curiosity,
Greg.

Interesting question worth a

Dodge Main : Metal welding line started out he 8th floor and worked it's way down. cross supports, rocker, floor pan, gate (Quarter panel), roof etc...

For anyone that wants to study how the cars were assembled, take a virtual walk through the blueprints of the Hamtramck plant at http://www.loc.gov/pictures/item/MI0166/

You can get lost in there for hours.......

many welds that seem impossible to most are just done from one side with the inner piece connected to one elsctrode and a single point spot head presses and heats the point to make the weld.
I have done tons of these with my Lenco spot welders. that is probably the top line unit closest to the factory single electrode spotters..
worth the investment as there are always the best for duplicating the exact and i mean exact pattern of factory welds.
also a tip when doing double sided welds. you can run a flat 1/2" inner electrode so most of the melt is between the sheets and top and the back surface stays un deformed.but be sure to monitor and controll your current and timing.
most factory outer panels ran 4-5ooo amps for .003 seconds.
less current and longer is better for playing round with the final weld look.

Thanks very much for all the information. Very helpful and interesting.

Greg.