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72 Challenger Project #938066
02/26/11 03:20 PM
02/26/11 03:20 PM
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Spanaway, Washington State
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72 Challenger we bought at the end of 2008.
It is a 318 2bbl car with AC. Nothing special.
I have the original hood as well as the RT hood that is on the car.

6497804-100_2453.JPG (240 downloads)
Last edited by patosmith; 02/26/11 03:27 PM.
Re: 72 Challenger Project [Re: patosmith] #938067
02/26/11 03:25 PM
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Another shot from the rear.
Nice dent in the roof.

6497817-100_2454.JPG (181 downloads)
Last edited by patosmith; 02/26/11 03:28 PM.
Re: 72 Challenger Project [Re: patosmith] #938068
02/26/11 03:34 PM
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I knew the floors and trunk were toast.
Even though I have alot of garage area, I do not have alot of space if you catch my drift. So, I cannot totally tear down the car.
I started in the trunk.

6497843-100_2511.jpg (152 downloads)
Re: 72 Challenger Project [Re: patosmith] #938069
02/26/11 03:38 PM
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New trunk floor. I also decided to replace the filler panel below the rear window.

6497852-100_2528.jpg (172 downloads)
Re: 72 Challenger Project [Re: patosmith] #938070
02/26/11 04:00 PM
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Sorry for the shock! As you can tell, this is not a mopar.
Late summer 2009 I broke the motor in our 56 Chevy so I had to stop work on the Challenger to get it fixed. The radiator cap went between the blower drive belt and pulley with the end result being a bent crank snub.
I decided since it would be a total tear down that I would stroke the 350 to 383 and went with all new internals.... And radiator cap!

6497896-100_2943.JPG (144 downloads)
Last edited by patosmith; 02/26/11 04:01 PM.
Re: 72 Challenger Project [Re: patosmith] #938071
02/26/11 04:07 PM
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After the delay, I started in on the floors.

6497910-100_2486.JPG (146 downloads)
Re: 72 Challenger Project [Re: patosmith] #938072
02/26/11 04:26 PM
02/26/11 04:26 PM
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Washington
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Great pictures Pat.. Welcome to the site.. Keep them coming..

Dennis

Last edited by 19cuda73; 02/26/11 04:43 PM.
Re: 72 Challenger Project [Re: 19cuda73] #938073
02/26/11 10:50 PM
02/26/11 10:50 PM
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Third Stone from the Sun
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Nice work, love the 72's.
Scott


1972 Dodge Challenger Rallye
UNDER CONSTRUCTION
Re: 72 Challenger Project [Re: Scotts72Rallye] #938074
02/26/11 11:34 PM
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Long Island Ny
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nice i have a 72 as well, cant wait to get going on it like you.

Re: 72 Challenger Project [Re: varlo] #938075
02/27/11 08:39 AM
02/27/11 08:39 AM
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Vista, California
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I'm diggin' the side stripe.


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Re: 72 Challenger Project [Re: ChickMaggot] #938076
02/27/11 08:04 PM
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New floor pans

6500134-100_3465.JPG (182 downloads)
Re: 72 Challenger Project [Re: patosmith] #938077
02/27/11 08:08 PM
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After knocking the paint off the firewall, I figured I better investigate a little further after finding some pin holes and a rusted out spot above the master cylinder.

6500145-100_3432.JPG (115 downloads)
Re: 72 Challenger Project [Re: patosmith] #938078
02/27/11 08:13 PM
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Looky here.
Notice the little rodent nest?

6500159-100_3451.JPG (133 downloads)
Re: 72 Challenger Project [Re: patosmith] #938079
02/27/11 08:15 PM
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New AMD firewall in place and ready for welding. Also purchased new AMD upper cowl section.

6500165-100_3458.JPG (165 downloads)
Last edited by patosmith; 02/27/11 08:25 PM.
Re: 72 Challenger Project [Re: patosmith] #938080
02/27/11 08:18 PM
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Decided to primer and paint before welding the new cowl and firewall together. This is primer, color will be black.

6500173-100_3460.JPG (130 downloads)
Re: 72 Challenger Project [Re: patosmith] #938081
02/27/11 08:23 PM
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New AMD sheetmetal under the rear seat. This was actually one of the easiest pieces I installed.

6500184-100_3466.JPG (121 downloads)
Last edited by patosmith; 02/27/11 08:24 PM.
Re: 72 Challenger Project [Re: patosmith] #938082
02/27/11 08:35 PM
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Does anybody repop or repair these for a 72? (Disregard the doors)
I can find the grill but not the rest of it.
This one is cracked and is missing a section where it meets up with the fender.

6500212-100_3461.JPG (148 downloads)
Last edited by patosmith; 02/27/11 08:36 PM.
Re: 72 Challenger Project [Re: patosmith] #938083
02/27/11 08:37 PM
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Another shot.

6500217-100_3462.JPG (111 downloads)
Re: 72 Challenger Project [Re: patosmith] #938084
01/01/12 02:17 PM
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Here's a shot with the quarter panel removed.
I treated the rust, primered and painted everything before the new panel was welded in place.

6995832-100_3477.JPG (108 downloads)
Re: 72 Challenger Project [Re: patosmith] #938085
01/01/12 02:42 PM
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I found a new nose piece on craigslist for a great price.

6995881-100_4015.JPG (134 downloads)
Re: 72 Challenger Project [Re: patosmith] #938086
01/01/12 02:46 PM
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Quarter panel in place.

6995891-100_4012.JPG (91 downloads)
Re: 72 Challenger Project [Re: patosmith] #938087
01/01/12 02:49 PM
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Now let's do the other side.

6995893-100_3716.JPG (109 downloads)
Re: 72 Challenger Project [Re: patosmith] #938088
01/01/12 02:52 PM
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A rusted out spot I fixed before the quarter was installed.
The "fixed" picture file size is too large to post.
I cut out all of the bad stuff, welded in new, Treated, primered and painted.

6995898-100_3717.JPG (106 downloads)
Last edited by patosmith; 01/01/12 02:59 PM.
Re: 72 Challenger Project [Re: patosmith] #938089
01/01/12 03:03 PM
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The edge of the tail piece was pretty sad.
I better fix that too.

6995927-100_3980.JPG (109 downloads)
Re: 72 Challenger Project [Re: patosmith] #938090
01/01/12 03:06 PM
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New piece being formed and fitted.
Once everything was welded up it was primered with weld thru primer.

6995936-100_3981.JPG (94 downloads)
Re: 72 Challenger Project [Re: patosmith] #938091
01/01/12 03:18 PM
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Done. ready for the quarter panel.

Re: 72 Challenger Project [Re: patosmith] #938092
01/01/12 03:22 PM
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Inside of quarter panel was primered, painted and the perimeter was hit with weld thru primer. This was done to the driver's side too.
This is an AMD part.

Re: 72 Challenger Project [Re: patosmith] #938093
01/01/12 03:28 PM
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Quarter panel in place.
The quarter panels I purchased from AMD.
This quarter panel had to be tweeked a couple of times before it would fit correctly. I had trouble in the area where it meets the rear window and surrounding area.
The other quarter fit without much work.
I think the AMD pieces are great.

6995980-100_4014.JPG (75 downloads)
Re: 72 Challenger Project [Re: patosmith] #938094
01/01/12 03:39 PM
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Let's move on to the roof...
I had hoped that I could treat and repair any rust damage without removing the roof.

6996001-100_3425.JPG (107 downloads)
Re: 72 Challenger Project [Re: patosmith] #938095
01/01/12 03:49 PM
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Previously I thought I could fix the rusted out metal here without removing the roof.
After seeing more rust while working on the quarter panels I knew I had best remove the roof. Luckily I did. I had rust starting to come thru the roof on the passenger side in 2 spots just above the door and windshield. When I removed the lead from where the roof and passenger side quarter panel meet a spot blew out just under the lead about the size of a half dollar coin.

6996028-100_3725.JPG (91 downloads)
Re: 72 Challenger Project [Re: patosmith] #938096
01/01/12 03:52 PM
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Another shot of the driver side.

6996042-100_3975.JPG (85 downloads)
Re: 72 Challenger Project [Re: patosmith] #938097
01/01/12 03:56 PM
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They don't repop the structure pieces that go from front to back yet. I had to take the pieces down to a local restoration shop to have them make the pieces for me. I could have done it if I had the proper shop equipment. They did a great job. The pieces fit with minimal hassle.

6996046-100_3979.JPG (91 downloads)
Re: 72 Challenger Project [Re: patosmith] #938098
01/01/12 04:07 PM
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I had a little repair work to do before I weld in the new pieces.

Re: 72 Challenger Project [Re: patosmith] #938099
01/01/12 04:13 PM
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Tacking in a patch. It was then welded, smoothed, treated and primered.

6996085-100_3978.JPG (78 downloads)
Re: 72 Challenger Project [Re: patosmith] #938100
01/01/12 04:18 PM
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Patch completed and the new pieces welded in place. Better than new since I treated and primered everything inside and out.
The passenger side was not this bad so it will not be this involved.
Kind of strange since the roof was rusting out on the passenger side.

More to come.
I will be ordering the roof and drip rails from AMD in the next month or so. I will post that adventure as it happens!

Last edited by patosmith; 01/01/12 04:22 PM.
Re: 72 Challenger Project [Re: patosmith] #938101
01/02/12 01:30 PM
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Nice job! Looking forward to seeing the rest of this build as it progresses.

Re: 72 Challenger Project [Re: JDMopar] #938102
01/13/12 11:04 AM
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You are making metal replacement look easy!
Nice Job


Looking for affordable 72-74 Cuda parts
Re: 72 Challenger Project [Re: rocksmopar] #938103
01/15/12 09:37 PM
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you rock


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Re: 72 Challenger Project [Re: aspenrt360] #938104
04/15/12 12:55 PM
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Test fitting the new roof I purchased from AMD.

7165659-100_4045.JPG (83 downloads)
Re: 72 Challenger Project [Re: patosmith] #938105
04/15/12 01:02 PM
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Took a little doing to position the roof rails in the right spot but I took my time and the roof installation turned out great without much of a problem.
I plan to use lead where the roof and quarters meet.

7165670-100_4046.JPG (81 downloads)
Re: 72 Challenger Project [Re: patosmith] #938106
04/15/12 01:11 PM
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Now that the roof is on, I bought door skins for both doors.
Before I do that, I want to get the front fenders in order.
I sanded off the paint and I found pools of filler which had to come out.
The fenders have more waves that the Pacific Ocean. The previous owner beat in the high spots and filled it with bondo.
I am in the process of grafting in lower patch panels and I plan some hammer and dolly time.
More to come on the fenders as they progress.

7165682-100_4049.JPG (71 downloads)
Re: 72 Challenger Project [Re: patosmith] #938107
02/04/13 11:03 PM
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I got tired of pounding on the front fenders so I bought a new pair from AMD. The originals were in such bad shape.

Re: 72 Challenger Project [Re: patosmith] #938108
02/04/13 11:06 PM
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Now that I have the fenders under control it is time to get the hood in shape. Oh no, the hood is rusting out and I found it loaded with bondo.

Re: 72 Challenger Project [Re: patosmith] #938109
02/04/13 11:09 PM
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Here is a shot of the hood support frame after I seperated it from the skin. I put my thumb through a section of the support. This hood is no good.

Re: 72 Challenger Project [Re: patosmith] #938110
02/04/13 11:14 PM
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I decided to try something different. I took a flat hood and added a 3 inch high cowl scoop. Here I am fitting the scoop.

Re: 72 Challenger Project [Re: patosmith] #938111
02/04/13 11:15 PM
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Another shot with it welded in place.

Re: 72 Challenger Project [Re: patosmith] #938112
02/04/13 11:17 PM
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In primer and ready to go.

Re: 72 Challenger Project [Re: patosmith] #938113
02/04/13 11:21 PM
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Here it is on the car.
Now that the sheetmetal is just about done I hope to start blocking it out and getting ready for paint.
I also need to think about getting the motor built and suspension together.
More to come.

Re: 72 Challenger Project [Re: patosmith] #938114
02/05/13 11:37 PM
02/05/13 11:37 PM

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Nice work.
Dealing with rust and damage sure gets tiresome after awhile. Keep up the good work.

Re: 72 Challenger Project [Re: patosmith] #938115
02/06/13 01:35 AM
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Awesome work. I would love to see more pic of how you did the firewall replacement. Did you leave the majority of the front clip on while putting the firewall on?

Re: 72 Challenger Project [Re: moparmojo] #938116
02/06/13 10:31 AM
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NV69B7RR  Offline
master

Joined: Nov 2006
Posts: 6,005
Reno, Nevada
Great work so far, looks like its come a long way. Keep up the great work, looking forward to seeing more progress. What are your plans for the drivetrain??

Re: 72 Challenger Project [Re: patosmith] #938117
02/07/13 06:52 PM
02/07/13 06:52 PM
Joined: May 2008
Posts: 2,107
Third Stone from the Sun
Scotts72Rallye Offline
top fuel
Scotts72Rallye  Offline
top fuel

Joined: May 2008
Posts: 2,107
Third Stone from the Sun
Quote:

I got tired of pounding on the front fenders so I bought a new pair from AMD. The originals were in such bad shape.


How was the fit of the fenders? Also,GREAT job with the hood!

Scott


1972 Dodge Challenger Rallye
UNDER CONSTRUCTION
Re: 72 Challenger Project [Re: moparmojo] #938118
02/08/13 11:43 AM
02/08/13 11:43 AM
Joined: Feb 2011
Posts: 293
Spanaway, Washington State
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patosmith Offline OP
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patosmith  Offline OP
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Spanaway, Washington State
Quote:

Awesome work. I would love to see more pic of how you did the firewall replacement. Did you leave the majority of the front clip on while putting the firewall on?



I thought I had taken pictures with the firewall out but evidently I didn't. Here is one of the firewall clamped together ready for welding. I braced the car from underneath so there wouldn't be any movement then removed the old one by drilling out the spot welds.
The AMD stuff fit real well and it went together easier than I thought it would. I left the inner fenders on but removed the brace that attaches them to the firewall. Before I was done welding I put the windshield in place to make sure things weren't twisted and out of place.

7580036-100_3456.JPG (50 downloads)
Re: 72 Challenger Project [Re: patosmith] #938119
02/08/13 01:05 PM
02/08/13 01:05 PM
Joined: Nov 2003
Posts: 5,048
Atlanta Indiana
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Dave Watt Offline
master
Dave Watt  Offline
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Joined: Nov 2003
Posts: 5,048
Atlanta Indiana
Looks great Pat. I really enjoy the step by step photos.

Re: 72 Challenger Project [Re: patosmith] #938120
02/08/13 04:20 PM
02/08/13 04:20 PM
Joined: Jan 2003
Posts: 1,232
Chicago, IL
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PLUM_72 Offline
pro stock
PLUM_72  Offline
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Joined: Jan 2003
Posts: 1,232
Chicago, IL
Looks great Pat! Id love to know more details about the quarter panel replacement. Did everything align and fit well together? Did you encounter any issues?

I have a 72 Challenger where the quarters were replaced with patch panels back around 1990. Sheet metal wasn't great back then. I've always been disappointed with the fit and finish of the quarter work and was thinking about having it done again with the AMD panels. The blend on my car between the factory door and the patch panel quarter isn't great. Especially at the body line, the lines just were not as crisp as they should have been.


1972 Dodge Challenger
Re: 72 Challenger Project [Re: PLUM_72] #938121
02/08/13 10:30 PM
02/08/13 10:30 PM
Joined: Feb 2011
Posts: 293
Spanaway, Washington State
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patosmith Offline OP
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patosmith  Offline OP
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Spanaway, Washington State
Quote:

Looks great Pat! Id love to know more details about the quarter panel replacement. Did everything align and fit well together? Did you encounter any issues?

I have a 72 Challenger where the quarters were replaced with patch panels back around 1990. Sheet metal wasn't great back then. I've always been disappointed with the fit and finish of the quarter work and was thinking about having it done again with the AMD panels. The blend on my car between the factory door and the patch panel quarter isn't great. Especially at the body line, the lines just were not as crisp as they should have been.



The AMD stuff fit really well. I used the full quarter, not the partial one. It is more money but I rather break welds at the existing seams and re-weld than trying to patch the partial one in. Just take your time and make sure everything lines up before you weld it in. The full quarter meets at the roof, trunk gutter, tail, rear wheel well, door jam, rocker, the deck below the rear window and part of the rear window opening itself. Lots of areas to make sure the fit is right but once you clamp it everywhere (use lots of clamps) and double check, it fits real well. Where the roof meets the quarter panel, you will need to remove the lead to get to the spot welds. I replaced the lead rather than use a thick layer of filler. Just seems better to me. Eastwood has a good lead kit with a DVD. I learned on an old piece of sheetmetal I had laying around. Kind of scary appying heat to sheetmetal but I didn't have any problems. I think the trick is not to get the metal so hot it changes color. Feel free to contact me for more details if you like. I have replaced just about every piece of sheetmetal on this car.

7580802-100_3716.JPG (51 downloads)
Last edited by patosmith; 02/08/13 10:35 PM.
Re: 72 Challenger Project [Re: PLUM_72] #938122
02/08/13 10:34 PM
02/08/13 10:34 PM
Joined: Feb 2011
Posts: 293
Spanaway, Washington State
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patosmith Offline OP
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patosmith  Offline OP
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Spanaway, Washington State
Quote:

Looks great Pat! Id love to know more details about the quarter panel replacement. Did everything align and fit well together? Did you encounter any issues?

I have a 72 Challenger where the quarters were replaced with patch panels back around 1990. Sheet metal wasn't great back then. I've always been disappointed with the fit and finish of the quarter work and was thinking about having it done again with the AMD panels. The blend on my car between the factory door and the patch panel quarter isn't great. Especially at the body line, the lines just were not as crisp as they should have been.



Here is the quarter before installation. I painted the inside then used weld thru primer at the weld locations.

Re: 72 Challenger Project [Re: NV69B7RR] #938123
02/09/13 11:22 AM
02/09/13 11:22 AM
Joined: Feb 2011
Posts: 293
Spanaway, Washington State
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patosmith Offline OP
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patosmith  Offline OP
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Posts: 293
Spanaway, Washington State
Quote:

Great work so far, looks like its come a long way. Keep up the great work, looking forward to seeing more progress. What are your plans for the drivetrain??



Thank you. I look forward to the body work to come to an end. I am more of a mechanic and I can't wait to get going on the drivetrain. I would like to get the car into the mid to upper 10's.
I have a 400 BB which I tore down to the bare block. If the block is ok the plan is to stroke it. A local tranny guy will build me a stout 727. The car came with a 8 3/4 rear with a 742 center which will need rebuilding with larger axles and possibly shortened. I may find a donor rear and put the original one away...

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