Modern Bullitt build

Posted by: Keepat

Modern Bullitt build - 05/01/14 05:58 PM

I started the restoration of my 1968 Dodge Charger with a plan to build a modern Bullitt. The outside of the car will look like the movie car with exception to the wheels, tires and a lower stances.
Im planning on a set of one off 17 wheels to match the look of the hubcaps use on the Bullitt Charger. This will allow larger brakes and wider tires. This hubcap was made to look like a mag wheel and now
Im going to have a wheel made to look like a hubcap. The motor will be a gen III Hemi 6.4 or the new Hellcat if it would fit under the stock hood? And a 6 speed manual trans. I have a lot of details to work out but for now
I will bag and tag the parts and get the car media blasted.
Thanks
Pat





This how car looked when I bought it a 1 years ago.




And now the parts start coming off!
Posted by: Turbo224

Re: Modern Bullitt build - 05/02/14 10:39 AM

Looks like a pretty clean car to start your project with. Looking forward to pictures!
Posted by: burdar

Re: Modern Bullitt build - 05/02/14 01:39 PM

I like the concept! I'll be watching.
Posted by: Duster08

Re: Modern Bullitt build - 05/05/14 10:47 AM

Sweet ride
Posted by: Keepat

Re: Modern Bullitt build - 05/21/14 08:07 AM

Still bagging and tagging the charger so I can get the car to the media blaster. Overall the car is in great shape with all of its original sheet metal and no accidents. The front fenders have never been off the car as I had to remove the great factory undercoating to get to the fasteners for the splash guards. The media blaster Im sure will uncover a few surprises. But for now here is the Good the Bad and the Ugly to date.
The Good, all of the frame rails are in excellent condition with only one small area of rust on the right side trans cross member and no accidents front or rear.

The Bad, a little rust on the drivers side floor that will take an 8 x 12 patch panel








And the Ugly, I knew I would be replacing the trunk floor when I bought the car, but the back yard patch job is Ugly! On the good side both trunk drop and frame rails are rust free.





Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 05/21/14 09:06 PM

I received the 1st rendering of the custom wheel Im having made to look like the hubcaps used on the Bullitt Charger. There are a few small changes that need to be made, such as the center emblem is not orientated correctly. There will be a tool that will fit the emblem which will allow access to the lug-nuts. Im very happy with the 1st drawings of this one off wheel and look forward to seeing them made.

This is the original hubcap


And here is the custom version of the hubcap






Thanks
Pat
Posted by: bobbyb

Re: Modern Bullitt build - 05/22/14 06:47 AM

Cool I like the wheels.
Posted by: 69charger440_6pa

Re: Modern Bullitt build - 05/22/14 11:25 AM

Great job on the wheels, I like them alot!! Can't wait to see this car come together. I loved your last car, lots of inspiration for my current build is coming from your old ride.
Posted by: Keepat

Re: Modern Bullitt build - 05/23/14 08:21 PM

Quote:

Great job on the wheels, I like them alot!! Can't wait to see this car come together. I loved your last car, lots of inspiration for my current build is coming from your old ride.




Yeah I enjoyed that first charger so much I decided to do it again, this one I'm sure will be a lot easier because the first one was a basket case as it was already disassembled before I bought it.
Thank you!
Pat
Posted by: ihv800

Re: Modern Bullitt build - 05/23/14 09:51 PM

I've dreamt of building a Bullitt Charger for a long time. I've tossed plans around on what to do about wheels. I like the looks of the wheel covers, but am a bigger fan of styled wheels. I always thought how awesome it would be to have some custom wheels made that mimicked the full wheel covers. Those will be sweet, and in my opinion make the look of the car! Look forward to all you do to it.
Posted by: Keepat

Re: Modern Bullitt build - 05/24/14 10:24 AM

I have been trying to restore the parts as I remove them instead of at the end of the project. The left side vent box is the last item I did and it cleaned up nicely. Here are a few before and after pictures.
Thanks!
Pat











Posted by: Keepat

Re: Modern Bullitt build - 05/27/14 09:54 PM

Received a few more wheel drawing with the logo upright and the black around the cut outs removed. Next drawings will have the extra material remove that was black as I think it may look better??


This is the front wheel 17x9 with a 5 back space





And this is the back wheel 17x11 with a 6 back space
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 05/28/14 06:15 PM

This is the final design of the wheel and the order is in! No black in the openings and the openings are larger. I should see them in 6 to 8 weeks.
Thanks!
Pat



Posted by: hemidart1

Re: Modern Bullitt build - 05/28/14 06:22 PM

Very cool
Posted by: RUNCHARGER

Re: Modern Bullitt build - 05/28/14 08:51 PM

Love the wheels and restoring the parts when pulling them is the best strategy to avoid getting overwhelmed when the car is all apart and everything is dirty. That's why projects sit for years and then get sold.

Sheldon
Posted by: Keepat

Re: Modern Bullitt build - 05/29/14 06:29 PM

Disassembled both doors so I can send out the vent window and door handles for re-chroming. Here are a few picture of the left doors hardware cleaned and painted along with the right doors hardware as it came out.






I remembered from my last 68 charger that reproduction the tail light gaskets didnt fit well. This time I was able to remove the original gasket without much damage and used an upholstery steamer to expand the foam. Then I sprayed a few coats of Plasti-Dip to fill in any damage. They should work like new!

Thanks
Pat



Posted by: Keepat

Re: Modern Bullitt build - 06/08/14 08:50 PM

Still removing and restoring as I go, but not much photogenic stuff to post. One of the things I restored was the rearview mirror and I took a few pictures of my sons 68 mustang with it.











Soon my Charger will look as good as his Fastback but it will be a lot faster ;-)
Thanks!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 06/13/14 05:55 PM

Received my tires yesterday, 255/45 and 335/35. Hope to get the wheels in a few weeks, then I can test
fit the front wheel/tires but will have to wait until I mini tub the rear to see the back wheels/tires under the car.
Thanks!
Pat





Posted by: mickm

Re: Modern Bullitt build - 06/18/14 04:35 PM

those 355's are massive! how do you plan on getting them under there, are you going to mini tub it?
Posted by: Keepat

Re: Modern Bullitt build - 06/20/14 06:10 PM

Quote:

those 355's are massive! how do you plan on getting them under there, are you going to mini tub it?




Yes, mini tub and RMS 4 link. As the trunk is rusted and is the only part of the floor that needs to be replaced that'll give me the room to work in the tubs with the old floor out.
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 06/30/14 02:59 PM

I skinned the charger and found a little rust around the back window but the front window channel looks great!












I also pulled the motor and Trans, as I sold it. With the motor in the car and still running I put it on Craigslist with a video and the 2nd called bought it! The 1st called was pissed.
Thanks
Pat







Posted by: cdp

Re: Modern Bullitt build - 06/30/14 09:20 PM

who are you sending your vent window parts off to for rechroming?
Posted by: Keepat

Re: Modern Bullitt build - 06/30/14 10:10 PM

Quote:

who are you sending your vent window parts off to for rechroming?




The past three cars I used Paul's Chrome And this will be the 4th car! Not cheap but I'm not sure you'll find better chrome work and pot metal repair work anywhere else.
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/13/14 07:13 PM

Went to Chrysler Carlisle and picked up a AMD trunk floor and US Car Tool chassis stiffening kit and mini tub kit and a few other things. It was hot but a great day!



Posted by: Keepat

Re: Modern Bullitt build - 07/13/14 08:10 PM

Removed the glue and green paint from the fuel fill pipe and sanded the lead coating with 400- 600 and 800 then clear coated it. Note use a respirator and glove when sanding lead.



Posted by: Keepat

Re: Modern Bullitt build - 07/20/14 11:09 PM

With the car still on all 4 I started fitting the US car tool frame connectors and after a little grinding they fit pretty well.








I also started on the only part of the frame that was rusted. The right side of the cross member needed a small section cut out and replaced so I found a donor frame rail to graft in the frame.












I will weld up after I finish cleaning the undercoat off.
Thanks
Pat
Posted by: Superfreak

Re: Modern Bullitt build - 07/21/14 08:17 PM

Looks good.
You're moving right along.
Posted by: cdstl

Re: Modern Bullitt build - 07/22/14 07:16 AM

Quote:

I have been trying to restore the parts as I remove them instead of at the end of the project. The left side vent box is the last item I did and it cleaned up nicely. Here are a few before and after pictures.
Thanks!
Pat
















Where did you get the rivets for the vent box? I am thinking about tinning and leading the galvanized parts on a heater box. Is that what you did with these pieces?

Thanks
Posted by: Keepat

Re: Modern Bullitt build - 07/26/14 03:33 PM

Quote:

Quote:

I have been trying to restore the parts as I remove them instead of at the end of the project. The left side vent box is the last item I did and it cleaned up nicely. Here are a few before and after pictures.
Thanks!
Pat
















Where did you get the rivets for the vent box? I am thinking about tinning and leading the galvanized parts on a heater box. Is that what you did with these pieces?

Thanks




I didn't remove the rivets just cleaned and cleared the parts
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/26/14 03:34 PM

Evod said the wheel should ship late next week and sent a picture of one of the center sections.
Thanks
Pat

Posted by: cdp

Re: Modern Bullitt build - 07/26/14 10:52 PM

sweet! Would love to see the same thing done with the 1970 dodge full wheel cover.
Posted by: Keepat

Re: Modern Bullitt build - 07/27/14 09:55 PM

I installed the US Car Tool core support today and fit great with just a little grinding. I order it without the holes as I like the original look. Next to the subframe connectors and torque boxes it is one the best stiffener you can add to a Mopar! I ground down and radiuses the weld so it would look original. You could jack the car up from the core support now!
Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 07/28/14 06:09 PM

I received another picture of my wheels today. This one with the complete center cap.
Thanks!
pat

Posted by: cdp

Re: Modern Bullitt build - 07/29/14 12:51 PM

Hmmm.... wouldn't it be nice if Ma-Mopar (Fiat) made available the new 707 HP supercharged Hemi as a crate motor with wiring/electronics for resto mods?

That would be a Bullitt for sure!
Posted by: Keepat

Re: Modern Bullitt build - 07/31/14 08:52 AM

I received a few more pictures of my front wheels. The red and black paint in the center cap should make them pop!
Thanks!
Pat





Posted by: Keepat

Re: Modern Bullitt build - 08/09/14 10:15 AM

Received the wheels Friday and they exceeded my expectations. I will paint the red and black details in the center cap soon and hope to get the tires mounted next week.
Thanks
Pat












Posted by: MuuMuu101

Re: Modern Bullitt build - 08/09/14 12:27 PM

So, are those centers going to be reproduced? I bet that will be another way to get the haters against big wheels to join the dark side. The Year One Rallye and Magnum wheels worked a little, but these things just look awesome.
Posted by: Keepat

Re: Modern Bullitt build - 08/10/14 03:48 PM

As it was a Dodge only hub cap for just a few years I'm not sure there will be enough demand for this wheel on the market to justify putting it in production. Selfishly I hope not ;-)
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 08/19/14 07:55 AM

Received some of the parts I sent to Pauls Chrome here are a few before and after pictures
Thanks
Pat











Posted by: MuuMuu101

Re: Modern Bullitt build - 08/19/14 06:32 PM

Quote:

As it was a Dodge only hub cap for just a few years I'm not sure there will be enough demand for this wheel on the market to justify putting it in production. Selfishly I hope not ;-)
Thanks
Pat




Remove the Dodge logo off the center and you won't have a Dodge only wheel but a good looking, aftermarket 5-spoke wheel.
Posted by: Keepat

Re: Modern Bullitt build - 08/21/14 08:46 PM

Im still working on the colors but I think it is close to the original hub cap colors. I also ordered the motor today, an aluminum gen III 6.1 Hemi stroked to 426 ci and about 650 hp
Thanks
Pat





Posted by: 6PKRTSE

Re: Modern Bullitt build - 08/22/14 09:14 AM

Those wheels are awesome even though I am not a fan of large dia wheels on musclecars. One of my dream cars is to also have a Bullit Clone 68 Charger someday. I'll bet those were not cheap.... Awesome decision to have them made.
Posted by: Keepat

Re: Modern Bullitt build - 08/29/14 09:22 PM

I finished the rust repair on the right side quarter panel, it required 3 small patch panels and a little fender well repair. The trunk floor extensions have some pits but require no repair just a coat of POR 15.
Thanks
Pat




























Posted by: Keepat

Re: Modern Bullitt build - 08/29/14 09:42 PM

I also had the tires mounted on the new wheels but I have yet to cut in the mini tub so I had to put the front wheels on the rear for pictures as the 12 wheel with the 335 tire dont fit the car yet.
Thanks
Pat





Posted by: Keepat

Re: Modern Bullitt build - 08/31/14 01:52 PM

I plan on testing a 3/16 black line on the outer rim as it is on the original hub cap. Im having 17 7/8x 3/16 vinyl ring made to check the look.



Posted by: Keepat

Re: Modern Bullitt build - 09/02/14 08:49 PM

I installed a vinyl black ring on one of the wheels to match the black line on the hub caps and I like the look. Hard to see the black line in the pictures but I think it finishes the look of the wheel.
Thanks
Pat










Posted by: Keepat

Re: Modern Bullitt build - 09/13/14 06:21 PM

Received my dash and door pads from Just Dashes and they look great. This is the 2nd Charger dash and door pads they have done for me just wish they could replicate the stiching :-( here are a few before and after pictures
Thanks
Pat





Posted by: Keepat

Re: Modern Bullitt build - 09/19/14 10:06 PM

Finished the rear valance and left rear quarter rust repair. One more rust spot on the front side of the left quarter to do then on to the trunk floor.


















Posted by: Dan Halen

Re: Modern Bullitt build - 09/23/14 08:34 PM

I've seen your old silver car,

This one will be even better!
Posted by: Keepat

Re: Modern Bullitt build - 09/24/14 05:56 PM

The silver Charger was a fun car to build that why I'm doing another one! Did you see the silver charger in person?
Thanks!
Pat

[IMG]http://i264.photobucket.com/albums/ii196/keepat/carstuff001.jpg~original[/IMG]




Posted by: Keepat

Re: Modern Bullitt build - 10/20/14 04:34 PM

Received a few pictures of the motor Indy is building for the charger. As soon as the 2nd FAST throttle body shows up I will drive out for the Dyno and bring it home.
Thanks
Pat








Posted by: Superfreak

Re: Modern Bullitt build - 10/20/14 09:59 PM

That looks pretty.
Posted by: MuuMuu101

Re: Modern Bullitt build - 10/20/14 10:09 PM

OoooOoooooOoo... Shiny.
Posted by: Keepat

Re: Modern Bullitt build - 10/22/14 10:23 PM

I de-torsion bar the charger, as Im going to use RMS coil over front suspension.
Thanks
Pat










Posted by: Keepat

Re: Modern Bullitt build - 10/28/14 09:09 PM

Added a cross member just forward of the leaf spring mounts. Used a 2 x 1 C channel cut and welded to fit in the floor tunnel under the rear seat. This should add additional rigidity to the chassis without impeding the driveshaft. Torque boxes are next.
Thanks
Pat











Posted by: Superfreak

Re: Modern Bullitt build - 10/28/14 11:55 PM

Nice work.
Posted by: Keepat

Re: Modern Bullitt build - 11/07/14 08:50 AM

Drove to Reilly Motorsports yesterday to pick up the front and rear suspension for the charger. Bill Reilly is a great guy and he had everything ready for pickup! Also stopped in Hazleton PA for the best chili dogs at Jimmys! I will post a few more picture of the RMS part when I get them out of the boxes.
Thanks
Pat





Posted by: Keepat

Re: Modern Bullitt build - 11/09/14 02:06 PM

Assembled the shocks using anti-seize and chased the threads on the upper control arms. Nice working on clean new stuff instead of old rusty stuff.
Thanks
Pat









Posted by: Keepat

Re: Modern Bullitt build - 11/12/14 10:24 PM

I assemble the new front wheel hubs, hats and the rotors. I used the same Wilwood 13 6 piston brakes on my last 68 Chargers and they worked great!
Thanks
Pat






Posted by: ihv800

Re: Modern Bullitt build - 11/13/14 09:47 PM

Build looks awesome. What is your procedure for metal finishing your welds down on the patch work? It looks fantastic!
Posted by: rhamson

Re: Modern Bullitt build - 11/14/14 08:41 AM

Looking good. I love the frame stiffening. You can't do enough in my estimation. More horsepower, more torque more trouble with these unibodies.
Posted by: Keepat

Re: Modern Bullitt build - 11/16/14 08:45 AM

Quote:

Build looks awesome. What is your procedure for metal finishing your welds down on the patch work? It looks fantastic!




I'm not sure I have any secret techniques that you can't already find online. The most important thing to remember is taking your time and don't let the panel get too hot. As I stitch weld I'd like to grind down the small welds close to the panel surface as I go Instead of grinding all the welds down when you're done. This helps keep the panel temperature low and It also helps when you're connecting the stitch welds as the panel thickness is more consistent with your amp setting on the welder.
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 11/23/14 09:27 AM

Picked up the new motor for the charger and watched a few pulls on the dyno yesterday at Indy Cylinder Head. The folks at Indy were great accommodating our dyno session and pick up on a Saturday.

The motor spec are, Aluminum 6.1 GEN 3 block that has a 4.125 bore and a 4.050 stroke, which makes it 433 ci. The crankshaft and H-beam rods are from Comstar. Diamond pistons are 10.5 to 1 and the 6.1 heads are fully CNC. Comp cam Hydraulic roller cam .572/.576 with .240/.244. MSD ignition and Fast EFI dual throttle bodies.

On 92 octane she had an average of 635 hp and 536 Lb ft of torque.
I'll post a few pictures later today

Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 11/23/14 08:30 PM

Here are a few pictures and a video of the dyno.
Thanks
Pat

[IMG]http://i949.photobucket.com/albums/ad340/kurts68fastback/th_79973DBE-60C6-4AED-B20D-C74BB0105DE6_zpsjomtn9ze.mp4[/IMG]








Posted by: moparpollack

Re: Modern Bullitt build - 11/23/14 10:18 PM

Sweet looking bullet!
Posted by: Keepat

Re: Modern Bullitt build - 11/26/14 10:03 PM

I put the Moser 9 rear together, I ordered 3.70 gears and a Detroit Truetrac differential.
Thanks
Pat












Posted by: rhamson

Re: Modern Bullitt build - 12/01/14 08:43 AM

Looks great Pat. This car will be a screamer.
Posted by: Keepat

Re: Modern Bullitt build - 12/02/14 07:26 PM

I move the Charger to Kurts Hot Rod shop to start the really dirty part of the restoration. I will do the body work and paint here as we did on my sons Mustang.
Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 12/04/14 06:01 PM

Received the T-56 6 speed transmission I ordered from Silver Sport Transmission today, along with the clutch, flywheel, peddles, and Quick time bell housing. So now I have most of the drivetrain component.
Thanks
Pat





Posted by: rhamson

Re: Modern Bullitt build - 12/05/14 08:40 AM

Sweet!
Posted by: Keepat

Re: Modern Bullitt build - 12/18/14 09:06 AM

Picked up a cool sissor lift for the shop and it will work get to put the motor in
Thanks
Pat

Posted by: brianz426

Re: Modern Bullitt build - 12/31/14 04:17 PM

Great job. Looking forward to the finished product.
Posted by: Keepat

Re: Modern Bullitt build - 01/03/15 07:11 PM

I have the factory undercoating remove from the back of the car. It is leveled and I added some reinforcements inside the car before I cut the frame for the spring location kit.
Thanks
Pat














Posted by: Keepat

Re: Modern Bullitt build - 01/04/15 09:57 PM

I cut the bottom of the US Car Tool spring relocation mount so they are flush with the frame and filled the lower holes. Then cut the rust free factory frame rails for the spring relocation mounts.
Thanks
Pat











Posted by: rhamson

Re: Modern Bullitt build - 01/08/15 11:27 AM

Looking Good Pat! When you are done I think this car could easily have outrun the Mustang.
Posted by: Keepat

Re: Modern Bullitt build - 01/10/15 10:06 PM

I have the spring relocation mounts installed. The US Car Tool spring mount have an alignment flange that bolts to the original forward spring perch but I had to cut it off as the Reilly Motorsport Street Lynx centers to the original frame (36 )









I used the frame cutouts to make templates to match the shape on the new spring mounts.







With spring mounts tacked welded on I will fit the upper crossbar before welding in.
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/14/15 04:17 PM

Before welding in the new RMS cross member I add a gusset inside the frame to help distribute the load to both side of the frame. I also had to make two shims to fill the small gap of the cross member.























I used a spot welded to hold the shim in place.






When it is welded in I will remove the original cross member.
Thanks
Pat
Posted by: hemi68charger

Re: Modern Bullitt build - 01/14/15 04:25 PM

Wow... Very impressive.. I dig the vision of the wheels.....
Posted by: Keepat

Re: Modern Bullitt build - 01/16/15 08:30 PM

Quote:

Wow... Very impressive.. I dig the vision of the wheels.....




Thank You sir!
Posted by: Keepat

Re: Modern Bullitt build - 01/16/15 08:32 PM

The Plasma cutter and spot weld cutter make short work of removing the right side inter wheel well. It would nice if it goes back in as easy, wishful thinking!
Thanks
Pat











Posted by: aspenrt360

Re: Modern Bullitt build - 01/16/15 08:34 PM

Really nice work! and the wheels are like art!
Posted by: mattsmopars

Re: Modern Bullitt build - 01/16/15 09:33 PM

Congrats! Very very nice charger!
Matt
Posted by: Keepat

Re: Modern Bullitt build - 01/18/15 08:03 PM

I test fit the 4 link rear today and put the rear wheels on the car for the 1st so I can setup the inter wheel wells. Its not quit the milestone of a car coming out of the paint booth, but seeing it with the wheels on and the right stance is a close 2nd!
Thanks
Pat
































Posted by: 69Cuda340S

Re: Modern Bullitt build - 01/19/15 09:03 AM

Excellent work!
Posted by: Keepat

Re: Modern Bullitt build - 01/19/15 05:02 PM

Quote:

Excellent work!




Thank you sir!
Posted by: Keepat

Re: Modern Bullitt build - 01/22/15 09:52 AM

Before the new trunk floor gets installed I moved the wheel well flange in 2 on each side to keep an original look to the floor.
Thanks
Pat



























Posted by: Keepat

Re: Modern Bullitt build - 02/06/15 09:33 PM

Remove what was left of the trunk floor and cut some dead weight out of the frame by removing the rear spring mounts. I also removed the left side trunk drop to do a little rust repair that I found when the trunk floor was removed. I couldve bought a new trunk drop but I enjoy saving as much of the original steel as I can.
Thanks
Pat

















Posted by: Keepat

Re: Modern Bullitt build - 02/22/15 08:49 PM

Out of town for a few days working at the Miami boat show, but got back on the Charger this weekend. Remove most of the paint, undercoating, and surface rust in the trunk.
Thanks
Pat










Heat-gun and a putty knife and then wipe down with lacquer thinner makes quick remove of the original sound deadening.








Posted by: moparpollack

Re: Modern Bullitt build - 02/22/15 10:44 PM

How do you plan to put the one piece trunk pan in? Just curious as I only seen it done with the quarters cut off.
Posted by: Keepat

Re: Modern Bullitt build - 02/23/15 08:49 AM

Quote:

How do you plan to put the one piece trunk pan in? Just curious as I only seen it done with the quarters cut off.




With the inter wheel wells out and the package tray cross braces removed the full trunk pan will go in from the back seat, then I will install the inter wheel well.
Thanks
Pat
Posted by: rhamson

Re: Modern Bullitt build - 02/25/15 09:16 AM

Nice work Pat! Keep it up.
Posted by: Keepat

Re: Modern Bullitt build - 02/28/15 10:10 AM

Before installing the trunk floor I started on the back window as it would be easier to clean up the welds under the window frame without the trunk floor.















Made a few template of the corner before cutting the rust out as to match the shape.






Welded in the lower half of the corner before cutting out the top half to help hold the shape.










Use the trim to confirm the shape as I tacked welded the new metal in.










One corner done and one to go.
Thanks
Pat
Posted by: Stewpar

Re: Modern Bullitt build - 02/28/15 10:48 AM

Very impressive to say the least, I am enjoying following this thread........
Posted by: Keepat

Re: Modern Bullitt build - 02/28/15 11:41 AM

Quote:

Very impressive to say the least, I am enjoying following this thread........




Thank you sir!
Posted by: 69Cuda340S

Re: Modern Bullitt build - 02/28/15 10:53 PM

Nice work on that window channel.
Posted by: Keepat

Re: Modern Bullitt build - 03/03/15 09:54 PM

The right side was a little more work but turned out nice.



















Next project is the trunk floor and mini tubs.
Thanks!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 03/07/15 10:09 PM

Test fit the trunk floor today so I can measure for the inner wheel wells. With the back seat cross braces removed and upper corners slightly bent up. The only other modification need was to bend the right side aft wheel well corner which I was planning on as I didnt weld that corner on yet in anticipation to a tight fit at the widest point of the trunk floor.
Thanks
Pat






























Posted by: Keepat

Re: Modern Bullitt build - 03/13/15 10:24 AM

Fit and butt welded the US Car Tool mini tub kit to one of the wheel wells. The left side fit great and Ill let you how the right side works soon. Would be nice if someone made wide stock looking wheel well like they have for GM & Ford cars!















I screwed on the extension to the outer wheel well. The shape of the kit is spot on!



















With the extension in place I screwed the inter wheel well on so I could remove it as one part to weld it together.

























Added about 2 to the wheel well, a lot of work for a 335 tire but it will look cool!
Thank you!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 03/14/15 10:08 PM

Finished the front wheel well floor flange and test fit the left wheel tub. Now on to the right side.
Thanks
Pat




















Posted by: 69charger440_6pa

Re: Modern Bullitt build - 03/14/15 11:43 PM

nicely done sir!
you are making me consider ripping my rear wheel wells out so I can do the same.
Posted by: RTSrunner

Re: Modern Bullitt build - 03/16/15 02:28 AM

Quote:

Really nice work! and the wheels are like art!




I agree.I always liked the style of that wheel cover,and as a wheel they are awesome! RT
Posted by: davesmopars

Re: Modern Bullitt build - 03/16/15 12:16 PM

Looks awesome! Nice work
Posted by: Keepat

Re: Modern Bullitt build - 03/16/15 07:54 PM

Thank you gentlemen!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 03/22/15 04:06 PM

Right side wheel well is finished and fits great.
Thanks
Pat














Posted by: 69charger440_6pa

Re: Modern Bullitt build - 03/23/15 12:17 PM

Best mini tub job I have ever seen. Looks factory.
Posted by: Keepat

Re: Modern Bullitt build - 03/23/15 07:01 PM

Quote:

Best mini tub job I have ever seen. Looks factory.




Thank you! It was a lot of work keeping it looking original but I think it was worth it!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 03/23/15 09:50 PM

US Car Tool supplied custom trunk hinge supports with the mini tub kit but Im not sure how they fit and they dont look right for this build so I modified the original mounts. I made a cardboard template and transferred the shape to the original mount. This finishes the original look I was working on.
Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 03/28/15 10:23 PM

With the inter wheel wells out the aft end of the rockers is open. So before they go in for good I vacuumed, cleaned , and sprayed Eastwood internal frame coating inside. Over 46 years old on the east coast they look great inside and now they should be good for another 46 years. I wonder if Ill be good for another 46 years??
Thanks
Pat

Before and after




Posted by: Keepat

Re: Modern Bullitt build - 04/05/15 08:35 PM

Epoxy the inside of the trunk and rear frame rails with DuPont 2505S DTM epoxy primer/sealer today.
Now its ready to weld the trunk floor and inter wheel wells in.
Thanks
Pat











Posted by: Stewpar

Re: Modern Bullitt build - 04/07/15 05:21 PM

Awesome!
Posted by: Keepat

Re: Modern Bullitt build - 04/11/15 06:12 PM

Welded in the trunk floor today and hope to put the inter wheel wells in tomorrow. The floor fit great with little persuasion. I was able put a bead of seam sealer at the tail panel and where the interior floor meets the trunk floor. I also used my spot weld wherever I could reach and plug welded what was left.
Thanks
Pat














Posted by: larry4406

Re: Modern Bullitt build - 04/11/15 06:43 PM

Nice. Details please on the spot welder.
Posted by: Keepat

Re: Modern Bullitt build - 04/12/15 12:28 PM

Larry,
The spot welder is a 220v Miller model LMSW 52T with timer control. It’s a nice unit but it is heavy and is best to use with 2 people. I have used it to restore 3 cars now and looks and works like new.
Thank You!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 04/12/15 08:45 PM

Epoxy primer the inter wheel wells along with few other parts today. I hope to install them permanently tomorrow.
Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 04/26/15 08:08 PM

I have been away from the Charger for a few days as my youngest graduated culinary school (CIA) in NY. He is only home for 3 weeks then back to school for a business degree.
I welded in the wheel wells and have the bumper & trunk supports painted and ready to install.
Thanks
Pat














Posted by: rhamson

Re: Modern Bullitt build - 04/27/15 08:27 AM

Looking good Pat. I think if the bad guy in Bullitt had been driving this one he might have gotten away.
Posted by: Keepat

Re: Modern Bullitt build - 04/27/15 06:57 PM

Thanks Ralph, hope you're making progress on your challenger!
Pat
Posted by: upnover

Re: Modern Bullitt build - 04/29/15 09:42 PM

looking good, lots of work!
Posted by: Keepat

Re: Modern Bullitt build - 04/29/15 09:55 PM

All the metalwork in the back of the car is complete and now it is time for the front of the car, motor, 6 speed, and RMS suspension. (The fun stuff)
Thanks
Pat





Posted by: Mopar Mark

Re: Modern Bullitt build - 04/29/15 10:50 PM

Are the supports that go from the "under the seat" floor section original or repro? If repro where can I find them?
Thanks,
Mark
Posted by: Keepat

Re: Modern Bullitt build - 04/29/15 11:08 PM

Only the trunk floor is reproduction, all the parts under the seat are original to this car. I would be surprised if the parts that you are looking for or not available. Good luck!
Thanks
Pat
Posted by: gregsrt

Re: Modern Bullitt build - 04/30/15 01:43 AM

Wow, that's some nice work there. I don't think it will ever rust now.
Posted by: Keepat

Re: Modern Bullitt build - 04/30/15 08:17 PM

I just remembered today marks one year into this build that I’m shooting to finish by next spring. It is so true how fast time fly’s by as we get older :-(
Pat
Posted by: rhamson

Re: Modern Bullitt build - 05/01/15 10:28 AM

Still on the rotisserie waiting to get some money for suspension parts to put her back on her wheels and start the body work. Thanks for asking.
Posted by: Keepat

Re: Modern Bullitt build - 05/04/15 08:53 AM

I drop the K member and remove the bump stops from the frame rails. The K member has SSBC disc brakes and is in good shape with a tight steering box and I would like to sell it if anyone is interested? I will post it for sale soon.
Thanks
Pat
















Posted by: Keepat

Re: Modern Bullitt build - 05/04/15 12:04 PM

I cut the bump stops off so that they could be reused on another car if someone needs a set?
Cleaned up the frame rails and fit the RMS K member.
Thanks
Pat



































Posted by: Keepat

Re: Modern Bullitt build - 05/04/15 09:46 PM

Even with all my calculations, double checking with the different venders, and other threads with similar suspensions it was a relief seeing the front wheel on the car with great clearance and no rubbing issues with in the fender.

Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 05/08/15 08:06 PM

I mocked up the steering U-joints and cut the shaft to fit, nice hardware supplied by RMS!
Thanks
Pat





Posted by: Keepat

Re: Modern Bullitt build - 05/13/15 11:05 PM

I started relief cutting the right side only of the trans tunnel to fit the T-56 transmission. I saw this method used on an E body in another forum and it looked like a clever way of disguising the modification of the trans tunnel to fit the big 6 speed.
Thanks
Pat











I attached a guide so I could make a straight cut with the plasma cutter.



















Posted by: NV69B7RR

Re: Modern Bullitt build - 05/14/15 09:34 AM

Nice work, I really like how you used the guide for making a clean cut. Can't wait to see your car finished!
Posted by: Keepat

Re: Modern Bullitt build - 05/16/15 07:56 PM

Fabricated an aluminum K member dolly as I will be installing and removing the motor and trans a lot over the next few week to fit the tunnel to the transmission.














I will have a scissor jack at the trans end to help adjust the fit in the car.




With K member dolly made I move the motor from the house to the Hot Rod shop. This is as close as the motor has gotten to the charger and it is about to get closer!
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 05/18/15 10:33 AM

Got to love a Plasma cutter! Used about 7 layers of tape for a guide and cut!
Thanks
Pat







[img]http://i949.photobucket.com/albums/ad340/kurts68fastback/th_IMG_3182_zpslqfcsvbc.mp4[/img]

Click on pic for video.




Posted by: 69Cuda340S

Re: Modern Bullitt build - 05/20/15 08:29 PM

Nice work!
Posted by: Keepat

Re: Modern Bullitt build - 05/23/15 09:39 PM

Installed the bell housing and transmission to the motor and set it up on the K member dolly. I think I will need to remove the right side valve cover to clear the right side inter fender. Tomorrow I will test fit the motor and trans in the car to check for tunnel clearances.
Thanks
Pat



















Posted by: minivan

Re: Modern Bullitt build - 05/23/15 10:22 PM

Dayum, that is coming out really nice...
Posted by: Keepat

Re: Modern Bullitt build - 05/24/15 09:55 AM

Just like my 1st Charger with the Ray Barton Gen 2 Hemi I needed to remove the right side valve cover to make it past the inter fender. I’m sure if the motor had stock valve covers it would have fit but the Indy valve covers are taller. Now I can start shaping the tunnel to fit the trans. With the lift and the fact that you can put the motor in from the bottom makes fitting and working on the tunnel a lot easier!





























I’m left with about 2 3/8” hood clearances, tight but it should work with a custom made air cleaner.
Thanks
Pat
Posted by: rhamson

Re: Modern Bullitt build - 05/27/15 01:14 PM

You do great work Pat! Keep it up.
Posted by: Keepat

Re: Modern Bullitt build - 05/28/15 02:56 PM

Originally Posted By rhamson
You do great work Pat! Keep it up.


Thanks Ralph!
Posted by: Keepat

Re: Modern Bullitt build - 05/28/15 02:57 PM

I have the trans tunnel tack-welded in place and ready to double check the trans fit.
I open the tunnel about 3” at the front and about 1 1/4” at the tail shaft. Now I need to make an removable shifter cover that will use the original shifter boot.
Thanks
Pat





























Posted by: rhamson

Re: Modern Bullitt build - 05/29/15 08:44 AM

Originally Posted By Keepat
I have the trans tunnel tack-welded in place and ready to double check the trans fit.
I open the tunnel about 3” at the front and about 1 1/4” at the tail shaft. Now I need to make an removable shifter cover that will use the original shifter boot.
Thanks
Pat




How are you keeping track of the drive shaft geometry? Since this transmission goes in much higher than stock, will it affect the pinion angle at the differential? Or are you going to equal the two out after you get the transmission set?



























Posted by: Keepat

Re: Modern Bullitt build - 05/30/15 02:10 PM

Ralph,
I have the angle of the of the trans set the same as the stock trans and will adjust to the rear as it will be lower then stock by 2" +/-
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 06/01/15 11:00 AM

The biggest part of the trans tunnel is finished and all that is left is lifting the aft end of the tunnel to meet the new height of the trans tunnel. But before that I’m starting on the cross member that will be made from 3/8 aluminum, I’ll post a few drawings of the cross member design soon.
Thanks
Pat




Posted by: Keepat

Re: Modern Bullitt build - 06/03/15 09:48 PM


Test fit the TTI headers and they fit great! Left side just touches the corner of the starter but there are no gasket installed yet and should clear when in. I also started on the cross member by making a plywood template. I should have it mocked up over the weekend and make the aluminum cross member next week.
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 06/07/15 09:41 AM

I finished mocking up the cross member with plywood and will duplicate in aluminum. This design will eliminate the need for the over the trans cross member. I think with a few modifications this cross member could also be used with a stock torsion bar suspension as well.
Thanks
Pat















Posted by: Keepat

Re: Modern Bullitt build - 06/12/15 11:33 PM

Had a friend weld the aluminum cross member for me and I think it looks great! With a little adjustment it fit as good as it looks!
Thanks
Pat















I add a flange at each end and I need to weld on the end caps to the original cross member. Also reused the original crush brace for the new hole I added for the cross member.








Posted by: Keepat

Re: Modern Bullitt build - 06/13/15 12:28 PM

For anyone interested here is a drawing of how I think this cross-member could be made to work with a stock torsion bar suspension.

Thanks

Pat




Posted by: minivan

Re: Modern Bullitt build - 06/13/15 09:36 PM

I always look forward to your posts and pic updates.. Amazing ideas and fab work...
Posted by: Keepat

Re: Modern Bullitt build - 06/13/15 09:45 PM

Originally Posted By minivan
I always look forward to your posts and pic updates.. Amazing ideas and fab work...


Thank you sir, I'm glad you enjoyed it.
Pat
Posted by: Keepat

Re: Modern Bullitt build - 06/14/15 09:32 PM


Cut the aft end of the trans tunnel and tacked it in place and now it is looking close to original.
Thanks
Pat















Posted by: Pacnorthcuda

Re: Modern Bullitt build - 06/14/15 10:08 PM

Is anybody else following this thread and thinking 'damn there are people on Moparts with amazing automotive skills' ?
Posted by: Mr. Smurf

Re: Modern Bullitt build - 06/15/15 09:36 AM

Yes....

Ed
Posted by: sparcy

Re: Modern Bullitt build - 06/15/15 11:22 PM

yep
Posted by: minivan

Re: Modern Bullitt build - 06/16/15 09:55 AM

Originally Posted By Pacnorthcuda
Is anybody else following this thread and thinking 'damn there are people on Moparts with amazing automotive skills' ?


Effin A... I know how much time and labor it took just to take one apart and put it back together like the factory did.. Lots of wire wheel time.....
Posted by: Keepat

Re: Modern Bullitt build - 06/16/15 03:52 PM

Thank you gentlemen! I'm glad you enjoyed it, thanks for following the progress.
Pat
Posted by: Keepat

Re: Modern Bullitt build - 06/17/15 08:13 PM

A few pictures of the new cross member installed with the transmission.
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 06/20/15 11:56 PM

I made a shifter cover with a similar shape as an original 4 speed cover using a wood block and a press. This will cover will be removable for shifter access.
Thanks
Pat



























Posted by: 2JcodeChargers

Re: Modern Bullitt build - 06/22/15 07:23 PM

Holy crap!
Pat, you're the man.
Posted by: Keepat

Re: Modern Bullitt build - 06/22/15 08:56 PM


This is the shifter that came with the T56 and I would like to find an original 1968 T handle shifter that I can modified the T handle to trigger a relay for the reverse lockout on the new trans. If anyone has one or knows where to get one please let me know. I’ll check at Carlisle in a few weeks.
Thanks
Pat











Posted by: JMCFAN

Re: Modern Bullitt build - 06/26/15 02:13 PM

Originally Posted By Pacnorthcuda
Is anybody else following this thread and thinking 'damn there are people on Moparts with amazing automotive skills' ?


yup!
Posted by: rhamson

Re: Modern Bullitt build - 06/27/15 12:12 PM

This is looking great Pat. You are an inspiration to just make it work.
Posted by: Keepat

Re: Modern Bullitt build - 06/28/15 04:19 PM

Test fit the hood today to check the clearance for the air cleaner and was happy to see there is 2 ½” at the front throttlebody and 3 ½” at the rear throttlebody. My earlier estimates were at about 2 3/8” and where an 1/8” more may not sound like much, it is a lot! Before ordering the modern-man Indy intake I could not find any info on the hood clearance other than the folks at Indy saying it will fit. Not sure it if would be the same with the stock K member?
Thanks
Pat







Posted by: rgreule

Re: Modern Bullitt build - 07/01/15 04:51 PM

awesome build!! keep up the good work
Posted by: Keepat

Re: Modern Bullitt build - 07/04/15 12:14 PM

Today I started fitting the backseat to see what modifications would be needed to fit the min-tubs. Both inter wheel wells have been moved inboard about 2 ½” each. After the 1st test fit I was pleasantly surprised to find very little modifications would be required, and most importantly the stock seat cover could be used!









The seat needed no modification as the seat frame cleared the wheel well.









The two tabs at the bottom of each wheel well needed to be moved to their original location. The tabs hold the seat back down.









These two metal rods need to be moved in about 1 ½” on each side to clear the wheel well.





Here you can see the 2 rods moved and the original rod to show the difference.





Fits great just need new black seat covers.
Thanks
Pat
Posted by: Hooligan

Re: Modern Bullitt build - 07/05/15 04:27 PM

Hi Pat!

I have been following your outrageous build with complete envy and utter disbelief of your amazing talent! I am a huge fan! Never before have I seen such gorgeous work done with incredible precision! I want to praise you a whole lot more, but now I want to thank you for the enjoyment that you are providing myself and to the other members who can't wait for more, more, more!

I have no negative thoughts or complains, but I have to wonder why you didn't use your spectacular imagination and skills to design and fabricate your own custom front and rear suspensions! Your terrific transmission cross member blew my mind away!

I am just starting a pro touring '72 Satellite, and you are a huge inspiration to me! I'll never reach the level of quality of your work! You stand alone in my opinion, and I have seen a lot of custom cars! I'm not impressed with the big name shops that build those high dollar cars with a team of guys and gals. I sure hope when you finish your Charger that you build another great Mopar!

Thanks again, Steve
Posted by: Keepat

Re: Modern Bullitt build - 07/05/15 10:44 PM

Originally Posted By sash7
Hi Pat!

I have been following your outrageous build with complete envy and utter disbelief of your amazing talent! I am a huge fan! Never before have I seen such gorgeous work done with incredible precision! I want to praise you a whole lot more, but now I want to thank you for the enjoyment that you are providing myself and to the other members who can't wait for more, more, more!

I have no negative thoughts or complains, but I have to wonder why you didn't use your spectacular imagination and skills to design and fabricate your own custom front and rear suspensions! Your terrific transmission cross member blew my mind away!

I am just starting a pro touring '72 Satellite, and you are a huge inspiration to me! I'll never reach the level of quality of your work! You stand alone in my opinion, and I have seen a lot of custom cars! I'm not impressed with the big name shops that build those high dollar cars with a team of guys and gals. I sure hope when you finish your Charger that you build another great Mopar!

Thanks again, Steve



Hi Steve,

Thank you for your comments and for following this build i'm glad you and others are enjoying it! As for designing and making my own suspension, "man must know his limitations" (Dirty Harry ;-)

The next car will be a old woody for my wife, but I'm not sure what make it will be? Could be another Mopar??


Good luck with your pro touring project, I'll look forward to watching your progress!

Thanks again for the kind words
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/11/15 09:43 PM

I picked up an aluminum air cleaner from Chris with Classic Haulage at Carlisle PA yesterday. Chris is a nice guy and he makes a great aluminum Hemi type air cleaner. A chrome plated repro of the original steel air cleaner is now available but as my motor is all aluminum I keep the aluminum theme. I need to make a custom filter base and get a 426 Hemi Head air cleaner sticker to finish the look.
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 07/18/15 08:51 PM

I removed the fenders and doors for the 1st time since the factory installed them in 1968. One of the things that attracted me to this car is it has all of its original body panels and has never been in an accident! The doors, fenders, trunk, hood, and a few other parts will go to the soda blaster Monday and the hinges will get shipped to SMS to be rebuilt. Interesting to find that the left and right fender had the same size shims with exception of 1 additional 1/16 shim on the bottom right rocker.
Thanks
Pat















Posted by: Keepat

Re: Modern Bullitt build - 07/24/15 09:16 PM

I received the Vintage Air system and fit the air handler on the firewall so I can mark the existing hole that I don’t need. The system comes with large plate to cover up the hole on the engine side but I plan on welding the holes and not using the plate.
Thanks
Pat






Posted by: Keepat

Re: Modern Bullitt build - 07/26/15 05:57 PM

The plan is to make some custom AC lines and run them in the right side fender well. But before I can start on the line I need to fit the US Car Tool inter fender brace. The fit was close but needed a little modification to fit great.









The problem with the fit was the factory welded the shock tower brace 3/8” forward from where it should be. To get the new brace to fit I cut about 3/8” off the front edge of the factory brace so the it would let the new brace slide back to meet the firewall and cowl.














Just a few screw to hold it in place and will weld it on with jack stand under the frame rails at the wheels. You can see how far off the factory mount is off in the last picture, I will re-cut the arch to match before welding.
Thanks
Pat
Posted by: 69Cuda340S

Re: Modern Bullitt build - 07/27/15 08:54 PM

Awesome work! Looking forward to seeing more progress!
Posted by: Keepat

Re: Modern Bullitt build - 08/02/15 09:31 AM

I picked up the doors, fenders, hood, and trunk from the media blaster and Epoxy sealed them with DuPont DTM primer/sealer. No surprises, panels look great only one spot of rust on the bottom of the right door.
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 08/09/15 04:16 PM

I started bending the stainless steel air conditioning lines that will be hidden under the right side fender, I will also make S/S heater lines to run under the fender.
Thanks
Pat















Posted by: Keepat

Re: Modern Bullitt build - 08/09/15 10:46 PM

The small AC line only took about 45 minutes as I had the 1st line to use for a template. Need to get a few fitting for the hot water lines this week.
Thanks
Pat







Posted by: Keepat

Re: Modern Bullitt build - 08/11/15 10:31 PM

I need two more fitting and I can finish the water lines. Now if I find a 3” mandrel pipe bender to borrow I could do the exhaust ;-)
Thanks
Pat







Posted by: rhamson

Re: Modern Bullitt build - 08/19/15 08:50 AM

Originally Posted By Keepat
I need two more fitting and I can finish the water lines. Now if I find a 3” mandrel pipe bender to borrow I could do the exhaust ;-)
Thanks
Pat





Looking good Pat. This will be the ultimate Charger.



Posted by: Keepat

Re: Modern Bullitt build - 08/19/15 08:05 PM

I received the back ordered EFI fuel tank from Tanks today. The tank looks stock but it is set up for an in tank fuel pump and it has baffles spot welded inside along with a 6” X 6” fuel tray. This looks like a nicely made tank for anyone putting a EFI system on their Charger!
Thanks
Pat















Posted by: Keepat

Re: Modern Bullitt build - 08/19/15 09:03 PM



Looking good Pat. This will be the ultimate Charger.

Thanks Ralph! I hope you're well and having a good summer.
Pat
Posted by: Keepat

Re: Modern Bullitt build - 08/25/15 08:02 PM

I finished test fitting the evaporator and making the heater and AC line inside the car. Welded 4 ¼-20 studs on the firewall and top of cowl to hold the evaporator instead of the through-bolts and screws. I also put the heater control valve under the dash hide it.
Thanks
Pat










Posted by: Keepat

Re: Modern Bullitt build - 08/27/15 09:11 PM

With the help of a few of the members from the DC forum I cut in the outboard dash AC vents use some great measurements, pictures, and part of an AC dash for an original template.
Thanks
Pat














Posted by: Keepat

Re: Modern Bullitt build - 08/28/15 09:55 PM

Finished the AC and heater lines at the motor, all that is left is one short line to make from the drier to the inter fender bulkhead fitting.







After bending the S/S line I had a friend weld the fitting on instead of silver soldering them on.

















The short braided soft lines for the heater and AC running forward and down will help to de-clutter the engine bay.
Thanks
Pat
Posted by: not_a_charger

Re: Modern Bullitt build - 08/29/15 10:42 AM

Of all of the cool cars I've seen on Moparts since I started coming here in 1999, this is my favorite, and by a wide margin. Thank you for taking the time to document this incredible build. Your talent is off the charts.
Posted by: Keepat

Re: Modern Bullitt build - 08/29/15 02:00 PM

Originally Posted By not_a_charger
Of all of the cool cars I've seen on Moparts since I started coming here in 1999, this is my favorite, and by a wide margin. Thank you for taking the time to document this incredible build. Your talent is off the charts.


Thank you! This car has been fun to build and I have enjoyed documenting and Posting the progress. Thank you for your comments.
Pat
Posted by: Hooligan

Re: Modern Bullitt build - 08/29/15 04:15 PM

Oh yes! It's a good thing that you have documented every aspect of your amazing build, because then you will know how to build another Charger when I take possession of this one! Ha-ha-ha! I am so envious of your awesome car and incredible skills! This is definitely the best build threat ever! There so much more great things to say, but I don't want to keep you from all the fun you are having, while providing us lucky members some wonderful entertainment! Go Pat go!
Posted by: Keepat

Re: Modern Bullitt build - 08/30/15 04:01 PM

Originally Posted By sash7
Oh yes! It's a good thing that you have documented every aspect of your amazing build, because then you will know how to build another Charger when I take possession of this one! Ha-ha-ha! I am so envious of your awesome car and incredible skills! This is definitely the best build threat ever! There so much more great things to say, but I don't want to keep you from all the fun you are having, while providing us lucky members some wonderful entertainment! Go Pat go!


Thank You sir!



Today I replaced the right side radiator core support so I can use the larger radiator. The new part fit nice and I spot-welded it in place. I hope to test fit the new radiator next week.
Thanks
Pat

















Posted by: Keepat

Re: Modern Bullitt build - 09/04/15 08:16 PM

All the AC lines are finished and the drier & condenser have been test fit. So far I’m very happy with the Vintage Air Mopar B Body system. I’m getting closer to putting the car on the rotisserie.
Thanks
Pat








Posted by: Satilite73

Re: Modern Bullitt build - 09/06/15 02:47 PM


I'm envious of your skills sir! bow

One question about the AC line routing, are you going to make some kind of cover/shield to protect them from road debris? My luck, a rock, or even worse, a blow out would take out all that hard work..... whiney


popcorn
Posted by: Keepat

Re: Modern Bullitt build - 09/06/15 03:22 PM

I had one bad spot in the right side cowl vent that needed a small repair, but fortunately it was accessible. The right side cowl vent is not used with new Vintage Air system; there is a plate that will cover it. Now I can water test it with a rust converter and spray it down with sealer. If anyone has a proven method for access, cleaning, and coating the inside of the cowl please let me know.
Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 09/06/15 03:40 PM

Originally Posted By Satilite73

I'm envious of your skills sir! bow

One question about the AC line routing, are you going to make some kind of cover/shield to protect them from road debris? My luck, a rock, or even worse, a blow out would take out all that hard work..... whiney


popcorn


The S/S lines are over kill for this job as they are rated for over 2500 PSI working pressure. I think they could take the shrapnel as good as the fender has for over 45 years. The AC lines will get a 3/16 neoprene insulator that will also help protect them as the undercoating protected the inside of the fender.
Thank You!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 09/08/15 10:02 PM

I fitted and welded in the left side US Car Tool inner fender brace. It needed a little massaging but fit really nice. Right side is next!
Thanks
Pat

















Posted by: Keepat

Re: Modern Bullitt build - 09/10/15 02:09 PM

I received my Griffin radiator yesterday so with the motor still in the car I test fitted it. I’m going to weld a 90 degree pipe on the thermostat housing so it will have a short top hose.
Thanks
Pat















Posted by: 69Cuda340S

Re: Modern Bullitt build - 09/13/15 09:06 AM

Originally Posted By Keepat
If anyone has a proven method for access, cleaning, and coating the inside of the cowl please let me know.


In threads over on the a-body forum I have seen people remove windshield and drill out all the outer cowl spot welds and remove top outer shell of cowl. Then you will have full access. Other than that you cant get in there.
Posted by: Keepat

Re: Modern Bullitt build - 09/16/15 04:54 PM

Disassembled the brake pedal assembly and added the clutch pedal. Next I will fit the assembly to the Hydroboost and hydraulic clutch.
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 09/19/15 10:21 AM

I test fitted the pedal assembly and had to weld over the original brake booster hole and cut a new hole in the firewall reinforcement mount. Also test fit the hydroboost and clutch master cylinder. I need to make the hydro boost and brake lines next.
Thanks
Pat

















Posted by: Keepat

Re: Modern Bullitt build - 09/24/15 11:29 AM

Mounted the clutch reservoir and used ¼ S/S tubing for the line.
Thanks
Pat








Posted by: Q5_Ed

Re: Modern Bullitt build - 09/25/15 04:26 AM

Very awsome project! Here is my cowl removed to repair old holes from racing in the top center of inner cowl. I hated to do it but only way to get full access. On a plus now can clen up vent holes correctly.
Posted by: Keepat

Re: Modern Bullitt build - 09/25/15 07:38 AM

Thanks for the great picture! Mine looks a lot like yours inside so I'm going to try to chemically treated without removing the cowl.
Thank you!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 09/27/15 07:30 PM

I bent the Hydroboost and power steering lines to fit in the left side inter fender well. I used 3/8” stainless steel .035 wall tubing. All this test fitting, wiring, and line bending just to pull it all out before the bodywork starts is a lot of work!! I’m sure I will enjoy having all this work behind me after the car is painted. Wait that sound like I’m looking forward to the bodywork ;-(
Thanks
Pat










Posted by: Keepat

Re: Modern Bullitt build - 10/02/15 07:36 PM

Went to Carlisle today and pickup my original front and back seats that I had dropped off with Legendary this past spring. They recover the front & back seat and I went with their Rallye front seat upgrade. I’m very happy with the look, shape, and fit!
Thanks
Pat








Posted by: SomeCarGuy

Re: Modern Bullitt build - 10/03/15 01:07 AM

Did you beef the lower rad support ala the old XV brace?
Posted by: Keepat

Re: Modern Bullitt build - 10/03/15 07:41 AM

Originally Posted By SomeCarGuy
Did you beef the lower rad support ala the old XV brace?


It is a US Car Tool lower rad support that I special ordered without the holes in it so it looks original. Fit and worked great!
Thank you!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 10/03/15 04:21 PM

I finished up the power steering lines and cooler. Front brake lines are next.
Thanks
Pat











Posted by: Q5_Ed

Re: Modern Bullitt build - 10/05/15 08:50 PM

Pat can you describe they method and tools, sanding grit etc. of how you stripped and clean paint on outside of inner fenders and framerails, firewall etc??
Also what was the blasters method and media used on doors etc?
How did you prep the metal before primer if anything?

Looking for some DIY tips!
Thanks
Ed B
Posted by: Keepat

Re: Modern Bullitt build - 10/05/15 09:39 PM

P
Originally Posted By Q5_Ed
Pat can you describe they method and tools, sanding grit etc. of how you stripped and clean paint on outside of inner fenders and framerails, firewall etc??
Also what was the blasters method and media used on doors etc?
How did you prep the metal before primer if anything?

Looking for some DIY tips!
Thanks
Ed B


Hi Ed, I started with a heat gun and putty knife to soften up and scrape off all the undercoating. Then I used some lacquer thinner and wiped off all of the leftover undercoating. Next I started with a 6 inch DA sander with 80 grit paper and also used a 3 inch DA sander for some of the tight spots. And lastly finished up using a 4" grinder with a wire wheel attachment for all the nooks and crannies.

The doors, fenders, hood and trunk lid we're all soda blasted. And you must clean and neutralize any of the soda residue with the product called hold tight before priming. Doors and fenders are easy because you can take them outside and power wash them with the hold tight. The hold tight also prevents any flash rusting as a result of the water.

I hope this helps and good luck with your project!
Thanks
Pat
Posted by: Black 69 Beeper

Re: Modern Bullitt build - 10/06/15 04:47 PM

Absolutely awesome work and just a stunning car even now.
Posted by: Keepat

Re: Modern Bullitt build - 10/06/15 08:11 PM

Originally Posted By Black 69 Beeper
Absolutely awesome work and just a stunning car even now.


Thank you sir! I'm looking forward to getting into paint as you are! What black are you using and who makes the paint?
Thanks again!
Pat
Posted by: Q5_Ed

Re: Modern Bullitt build - 10/09/15 09:44 PM

Thanks for the info
Posted by: Keepat

Re: Modern Bullitt build - 10/10/15 04:36 PM

I decided to go with aluminum for the AC and heater line covers. They will be painted with Bed-liner after a few seams are welded. I left the front cover long and will cut to fit the fender.
Thanks
Pat




















Posted by: SomeCarGuy

Re: Modern Bullitt build - 10/13/15 03:02 AM

Any idea on your hours involved on this?
Posted by: Keepat

Re: Modern Bullitt build - 10/13/15 05:04 PM

Originally Posted By SomeCarGuy
Any idea on your hours involved on this?


Hours in the full car project to date I'm not sure! hours to make the inter fender covers 7 hours
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 10/15/15 09:59 PM


Left side inter fender covers are fitted and just need a few seams welded. Getting close to pulling the motor and mount the body on the rotisserie.
Thanks
Pat

















Posted by: Black 69 Beeper

Re: Modern Bullitt build - 10/16/15 06:00 PM

I will be using PPG DBC basecoat/clearcoat. I would have done the whole car in DCC single stage but being that the roof is painted pewter I will do basecoat on the exterior. I used DCC single stage on the inside, trunk, and engine compartment.I mixed 50/50 with urethane clear on the last coat.
Posted by: Keepat

Re: Modern Bullitt build - 10/18/15 08:32 AM

Originally Posted By Black 69 Beeper
I will be using PPG DBC basecoat/clearcoat. I would have done the whole car in DCC single stage but being that the roof is painted pewter I will do basecoat on the exterior. I used DCC single stage on the inside, trunk, and engine compartment.I mixed 50/50 with urethane clear on the last coat.


The single stage paint certainly makes a lot of sense inside the car and the trunk area, I may do the same thing? On the bottom of the car friend of mine is a painter for commercial vehicles and they been using a clear coat that is graffiti proof and he has used it on the bottoms of cars that he's done and it make road grime clean up really easy. It sounds interesting and I need to look into that and see just how well it works.
Thank you
Pat
Posted by: Black 69 Beeper

Re: Modern Bullitt build - 10/18/15 12:15 PM

I know PPG makes a graffiti resistant paint that they use on New York city subway cars. I have a friend who is the local PPG rep. I could check with him as to what it is. I have become a friend of urethane truck bed liner coating. I did paint the underside of my car but after i finished i realized that i just don't want a trophy piece that I have to keep super clean. When sprayed with a schutz gun it looks like factory undercoating and is tough as nails. hit it with a hose and its all clean again. Plus its a sound deadener.
Posted by: Keepat

Re: Modern Bullitt build - 10/18/15 03:14 PM

Originally Posted By Black 69 Beeper
I know PPG makes a graffiti resistant paint that they use on New York city subway cars. I have a friend who is the local PPG rep. I could check with him as to what it is. I have become a friend of urethane truck bed liner coating. I did paint the underside of my car but after i finished i realized that i just don't want a trophy piece that I have to keep super clean. When sprayed with a schutz gun it looks like factory undercoating and is tough as nails. hit it with a hose and its all clean again. Plus its a sound deadener.


Any info from the PPG rep would great!
THANK YOU!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 10/23/15 09:51 AM

I started the pluming for the brakes by making the mounts for the line locks and proportional valve to go under the master cylinder to help hide it. I need to make room in the inner fender for the front brake line and I’ll do this to keep the lines clear of the motor.
Thanks
Pat















Posted by: Keepat

Re: Modern Bullitt build - 10/25/15 07:30 PM

I had a few people ask how I measure and bend the stainless steel tubing, so I thought I would post a little more details on the radiator overflow line. I have bent thousands of feet of S/S tubing over the years. Every 55 Fleming yacht commissioned on the east coast I have bent about 80 foot of ½” and ¼” tubing, all by measurements and drawings. I sure there are many different ways to bend S/S tubing but what I have found that works best for me is outside to outside tubing measurements. This is easy when working with 90 degree bends. In the pictures below you’ll see marks on the tubing. One is an parallel orientation line, then a line designating the outside of the tubing after the bend, and the last mark is a U or C (depending on how you look at it) this designate the direction the bend should go.










By using a 45 degree fitting in the neck of the radiator I was able to bend the tubing about 45 degree to start the line. With the first bend close to the flair its best to flare the line 1st as some flaring tools need more room then the bend will leave. You can see two marks in the 3rd picture, 1 marking the where the outside of the tubing will be and the other marking the direction of the bend.








Here I’m using a scrap piece of tubing to mark where I will make the bend, I also measure for the next bend and mark the orientation for this change indirection.


















[img]http://i949.photobucket.com/albums/...jicco.jpg[/img]



Posted by: Keepat

Re: Modern Bullitt build - 10/28/15 09:23 PM
























Here are the tools I used to bend and flare the S/S tubing
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 10/28/15 09:27 PM

There are 2 small computers that I needed to mount under the dash. One controls the EFI that I mounted on Vintage Air mount so that the troubleshooting light is just viewable under the dash (sorry no pictures) The 2nd controls the ignition and I mounted it to a plate that covers the unused right side cowl vent.
Thanks
Pat











Posted by: ihv800

Re: Modern Bullitt build - 10/30/15 10:32 PM

You're a phenomenal metal worker, and I love detail oriented stuff, this checks all the right boxes. All that tubing work is nothing short of incredible, simply art!
Posted by: Keepat

Re: Modern Bullitt build - 10/31/15 09:02 AM

Originally Posted By ihv800
You're a phenomenal metal worker, and I love detail oriented stuff, this checks all the right boxes. All that tubing work is nothing short of incredible, simply art!


Thank you sir!
Posted by: Keepat

Re: Modern Bullitt build - 11/14/15 09:46 AM

Pulled the motor back out so I could modify the inner fender to make room for one of the brake lines off the master cylinder.
Thanks
Pat





























Posted by: Keepat

Re: Modern Bullitt build - 11/15/15 01:25 PM

Welded the seams on the inner fender covers, coated them with bed liner and installed a rubber gasket I got from McMaster Carr. Now they should keep most of the water and dirt out.
Thanks
Pat













Posted by: Keepat

Re: Modern Bullitt build - 11/19/15 09:00 PM

I bent the right front brake line to run along the seam between the firewall and floor. This is much cleaner than the original run in the middle of the firewall.
Thanks
Pat




Posted by: mopar4don

Re: Modern Bullitt build - 11/20/15 07:20 AM

up Looks GREAT Pat
Posted by: Keepat

Re: Modern Bullitt build - 11/20/15 01:08 PM

Originally Posted By mopar4don
up Looks GREAT Pat


Thank You Don!
Posted by: Keepat

Re: Modern Bullitt build - 11/22/15 12:41 PM

Finished the left front brake line and started on the rear brake line. Fuel lines are next.
Thanks
Pat

















Posted by: Keepat

Re: Modern Bullitt build - 11/27/15 08:14 PM

It’s not a ported head intake runner, but it will have fuel running through it. What do you think it is?


Answer will be in the next post
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 11/27/15 08:44 PM

I needed to make a large fuel pass-through in the trans cross member as there will be two ½” fuel lines. I used part of the rear frame rail I cut off last winter to make the reinforcement for the hole I put in the cross member. Now I can bend full length fuel line to fit.
Thanks
Pat





























Posted by: Keepat

Re: Modern Bullitt build - 11/29/15 08:04 PM

I installed the fuel tank so I could mark the trunk access for the fuel pump and sending unit. The tank has a EFI pump inside and adding the trunk access will make it easy check or remove without dropping the tank.
Thanks
Pat

























Posted by: Keepat

Re: Modern Bullitt build - 12/01/15 08:59 PM

The fuel tank access cover is done, now I can bend the fuel lines
Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 12/03/15 08:37 PM

I received the new RMS rear sway bar kit today just in time before I bend the fuel lines. I will locate the sway bar mounts first, so I can route the lines around them. This kit has been in the works for over a year and it was worth the wait! It is a great looking kit and very reasonably priced!
Thanks
Pat


Posted by: Keepat

Re: Modern Bullitt build - 12/05/15 09:02 PM

I put the rear back in the car so I could fit the new RMS sway bar. The sway bar kit fit great after I quickly figured out it is a rear mount system. All the RMS sway bar prototypes I saw at Carlisle had front mounts. Bill said the kit will work with TTI 3” exhaust and it does look to have more than enough room.
Thanks
Pat














Posted by: Superfreak

Re: Modern Bullitt build - 12/06/15 10:40 AM

Nice work.
Posted by: Keepat

Re: Modern Bullitt build - 12/06/15 05:15 PM

Originally Posted By Superfreak
Nice work.


Thank you sir!
Posted by: Keepat

Re: Modern Bullitt build - 12/13/15 09:59 PM

I almost finished the fuel lines this weekend. Just one S/S line left to make and a few hose.
Thanks
Pat

















Posted by: Keepat

Re: Modern Bullitt build - 12/20/15 08:24 AM

I finished the rear fuel lines and all that is left is the Much II tank vent system.
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 12/23/15 08:17 PM

Before removing the fuel line I made an AC condensation drain and fire wall pass-through.
Thanks
Pat














Posted by: PasiR

Re: Modern Bullitt build - 12/25/15 05:11 AM

Very nice work and details - I like this!
Posted by: Keepat

Re: Modern Bullitt build - 12/25/15 06:02 PM

Originally Posted By PasiR
Very nice work and details - I like this!


Thank you sir, I appreciate your comment!
I hope you have a Great holiday!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 12/26/15 10:41 PM

Installed the II Much vent canister, starting with punching out a 2 ½” hole where there was a 1 ¾” body plug using a knockout punch tool. This is a clean way to put holes into steel panels. Then I bent a 3/8” S/S vent line running downhill to the two tank vent fittings. I step closer to starting the bodywork.
Thanks
Pat























Posted by: Darius

Re: Modern Bullitt build - 12/29/15 08:09 AM

Un believable creativity here Bro! This is so clean . Having built engineering scale models of Oil refineries and nuclear power plants I truly appreciate your piping design and layout. Perfection!
Posted by: Keepat

Re: Modern Bullitt build - 12/29/15 12:06 PM

Originally Posted By Darius
Un believable creativity here Bro! This is so clean . Having built engineering scale models of Oil refineries and nuclear power plants I truly appreciate your piping design and layout. Perfection!


Thank you! sound like you have a cool job or is it a hobby building scale models?
Pat
Posted by: Keepat

Re: Modern Bullitt build - 12/29/15 12:07 PM

Ok this is the last of the pluming work (for now ;-) Before I put all the tubing tools away I bent up the rear brake lines. As the rear has no brake line clips I made 2 weld on S/S straps to go on the U bolts and 2 S/S clips that I drilled and taped onto one of the 4 link mounts.
Thanks
Pat


















Posted by: Darius

Re: Modern Bullitt build - 12/29/15 04:10 PM

Originally Posted By Keepat
Originally Posted By Darius
Un believable creativity here Bro! This is so clean . Having built engineering scale models of Oil refineries and nuclear power plants I truly appreciate your piping design and layout. Perfection!


Thank you! sound like you have a cool job or is it a hobby building scale models?
Pat


It was a job I had in the late '70's. I worked at Ralph Parsons Engineering in Pasadena and Bechtel in San Francisco. Unfortunately ,the commute was so bad I decided to go back to cabinet making which led to me starting my own shop and I have been in the residential remodeling business ever since.
BIG fun building those models to perfecting scale as part of the design process. The models were then used on site by the contractors for 3d reference. It was one of those jobs where they had to kick me out at closing time.
Posted by: Keepat

Re: Modern Bullitt build - 01/02/16 12:29 PM

I put the charger on the rotisserie so I can finish the bottom and prime it. I also have a small floor repair.
Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 01/03/16 10:25 PM

Had a few helpers stop by the shop today ;-)
Pat



Posted by: tpabayflyer

Re: Modern Bullitt build - 01/04/16 01:17 PM

Yeah! They are waiting for you to finish so they can join you in a window down, B-body cruise!
Posted by: Bullitt Guy

Re: Modern Bullitt build - 01/04/16 02:52 PM

I have been following this build since last summer and am amazed at your attention to detail and fabrication. This is an amazing project.
I have a Bullitt replica that I restored in 2006, stock appearing with addition of some suspension upgrades.

http://vancouverclassiccars.com/VancouverClassicCars/DODGE_CHARGER.html

The car has this appearance full time now.

http://s285.photobucket.com/user/paulolds/media/Dodge%20Charger/IMG_3016.jpg.html

You should plan to bring your completed car to MCACN in Chicago when finished.

Paul
Posted by: Keepat

Re: Modern Bullitt build - 01/04/16 05:22 PM

Originally Posted By tpabayflyer
Yeah! They are waiting for you to finish so they can join you in a window down, B-body cruise!


They do like to cruise with the window down ;-)
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/04/16 05:27 PM

Originally Posted By Bullitt Guy
I have been following this build since last summer and am amazed at your attention to detail and fabrication. This is an amazing project.
I have a Bullitt replica that I restored in 2006, stock appearing with addition of some suspension upgrades.

http://vancouverclassiccars.com/VancouverClassicCars/DODGE_CHARGER.html

The car has this appearance full time now.

http://s285.photobucket.com/user/paulolds/media/Dodge%20Charger/IMG_3016.jpg.html

You should plan to bring your completed car to MCACN in Chicago when finished.

Paul



Paul,
Awesome Bullitt Charger you have!!! I hope my Charger looks as nice as yours 1 day! Thank you for links as it is always great to see other black 68 Chargers.
Thanks again!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/08/16 09:36 AM

Started installing the torque boxes and have the left aft welded in. The US Car Tool boxes fit nice and only need a little adjustment. I added a 1 ½” hole for a future rear brake vent.
Thanks

Pat














Posted by: mopar4don

Re: Modern Bullitt build - 01/08/16 09:40 AM

Keep them pics coming!
I absolutely love it!
Your thread helps me a lot as I will be adding these to my Charger
Posted by: Keepat

Re: Modern Bullitt build - 01/08/16 01:01 PM

Originally Posted By mopar4don
Keep them pics coming!
I absolutely love it!
Your thread helps me a lot as I will be adding these to my Charger


Don, You keep the pictures coming also, as I enjoy following your build!
Thank you!
Posted by: mopar4don

Re: Modern Bullitt build - 01/08/16 01:41 PM

Originally Posted By Keepat
Originally Posted By mopar4don
Keep them pics coming!
I absolutely love it!
Your thread helps me a lot as I will be adding these to my Charger


Don, You keep the pictures coming also, as I enjoy following your build!
Thank you!


Pat, It's obvious you've done this before.
Guys like me (novice) are learning from guys like you.
So thank you!
I will keep my pics coming on my build (I am behind)
Posted by: Keepat

Re: Modern Bullitt build - 01/10/16 07:47 PM

I started on the driveshaft loop/crossmember today. Using a press I oval a 2” section of 6” pipe and hammered the top half to match the shape of the driveshaft tunnel. With the loop clamped in place and using a 15” contour gauge (a must have tool) I made two cardboard pattern for the crossmember. With the cardboard center section of each pattern as wide as the square tubing (2”) I was able to lay it over the tubing to get a precise line to cut with the plasma cutter. I still need to make the pattern for inside the tunnel above the loop before I can weld it to the floor.
Thanks
Pat

























Posted by: sparcy

Re: Modern Bullitt build - 01/12/16 07:02 PM

AMAZING ABSOLUTELY AMAZING WORK !!! BEN FOLLOWING THIS RITE ALONG , MAKES ME WANT TO TAKE MY PROJECT TO THE NEXT LEVEL !!! LOVE IT !!!!!!
Posted by: Keepat

Re: Modern Bullitt build - 01/12/16 09:24 PM

Originally Posted By sparcy
AMAZING ABSOLUTELY AMAZING WORK !!! BEN FOLLOWING THIS RITE ALONG , MAKES ME WANT TO TAKE MY PROJECT TO THE NEXT LEVEL !!! LOVE IT !!!!!!


THANK YOU SIR ;-)
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/13/16 08:36 PM

The drive shaft loop/crossmember is made and tack welded in place. Back to the torque boxes.
Thanks
Pat














Posted by: Keepat

Re: Modern Bullitt build - 01/17/16 05:31 PM

Finished up a few details on the front of the frame connectors today. Front torque boxes are next.
Thanks
Pat
















Posted by: rhamson

Re: Modern Bullitt build - 01/19/16 02:24 PM

Good work Pat. I love the way over the top" engineering you are doing on this project. Patience is your virtue.
Posted by: Keepat

Re: Modern Bullitt build - 01/19/16 07:07 PM

Originally Posted By rhamson
Good work Pat. I love the way over the top" engineering you are doing on this project. Patience is your virtue.


Thank you Ralph, I hope you're well and move along with your challenge your project?
Pat
Posted by: PasiR

Re: Modern Bullitt build - 01/20/16 08:49 AM

Very nice driveshaft loop!
Posted by: Keepat

Re: Modern Bullitt build - 01/20/16 06:56 PM

Originally Posted By PasiR
Very nice driveshaft loop!


Thank You! I'm really happy with how it turned out.
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/22/16 09:23 AM

Fit and tack welded the right front torque box. Had to bend the US Car Tool torque box on an angle and added ¼” along the floor side to get a good fit. Both sides will need the same alteration to fit correctly.

Thanks
Pat























Posted by: CJD AUTOMOTIVE

Re: Modern Bullitt build - 01/22/16 11:03 AM

Been watching this one, and it is really turning out nice. Your attention to detail and fab skills is what separates this car from the rest. Too bad most will never notice or appreciate the time and skills required. Keep it up!!
Posted by: mopar4don

Re: Modern Bullitt build - 01/22/16 11:25 AM

I know for one, I APPRECIATE the time you take to show your work! It sure helps guys like me with there build.

Say Pat, can you tell me why your putting the torq boxes in now without the weight of the motor?
Posted by: tpabayflyer

Re: Modern Bullitt build - 01/22/16 12:33 PM

The driveshaft/extra crossmember is a fantastic idea and should help give your car roll cage like rigidity with all the extra supports you have installed to shore up the flimsy unibody! I also installed the subframe connectors/ torque boxes in my Challenger without any drivetrain installed. I'm not sure how the factory did this but I am sure it will lessen any amount of frame deflection and movement once the drivetrain is installed.... My car will be put on an alignment rack and setup for optimism performance so I am sure factory specs won't work for me......
Posted by: Keepat

Re: Modern Bullitt build - 01/22/16 03:51 PM

Originally Posted By CJD AUTOMOTIVE
Been watching this one, and it is really turning out nice. Your attention to detail and fab skills is what separates this car from the rest. Too bad most will never notice or appreciate the time and skills required. Keep it up!!


Thank you Craig!
Posted by: Keepat

Re: Modern Bullitt build - 01/22/16 03:56 PM

Originally Posted By mopar4don
I know for one, I APPRECIATE the time you take to show your work! It sure helps guys like me with there build.

Say Pat, can you tell me why your putting the torq boxes in now without the weight of the motor?


Don, I did install the frame connectors when the car was complete and on the ground, and with the frame connectors installed I didn't see any problem with adding torque boxes when the car was on the rotisserie. It is so much nicer welding right side up instead of upside down ;-)
Thank you!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/22/16 03:59 PM

Originally Posted By tpabayflyer
The driveshaft/extra crossmember is a fantastic idea and should help give your car roll cage like rigidity with all the extra supports you have installed to shore up the flimsy unibody! I also installed the subframe connectors/ torque boxes in my Challenger without any drivetrain installed. I'm not sure how the factory did this but I am sure it will lessen any amount of frame deflection and movement once the drivetrain is installed.... My car will be put on an alignment rack and setup for optimism performance so I am sure factory specs won't work for me......


I am very happy with the way the crossmember driveshaft loop came out and considering the modification I made to the factory crossmember I think it added a lot more rigidity to the frame. Thank you!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/28/16 09:06 AM

Installed the parking brake cable pass-through tube in the frame connector. I also remove the original floor mount for the parking cable as I’m going to install a small roller to redirect the cable along the frame.
Thanks
Pat

















Posted by: Keepat

Re: Modern Bullitt build - 02/01/16 09:37 PM



I had a small section of the driver’s side floor with pin holes that needed to be replaced. I cut about 18” from a new left side floor pan and grafted it along the cross member so it would be hard to tell if it was repaired. Some high-build primer should make any imperfections disappear.

















Posted by: Stewpar

Re: Modern Bullitt build - 02/02/16 09:30 PM

Pat:

I personally ignore this thread for periods of time so that I can spend more time looking at more pictures and updates. The work you do is amazing, your creativity and attention to detail are out of this world. I will be both happy and sad when this build is done!
Posted by: Keepat

Re: Modern Bullitt build - 02/03/16 09:08 AM

Originally Posted By Stewpar
Pat:

I personally ignore this thread for periods of time so that I can spend more time looking at more pictures and updates. The work you do is amazing, your creativity and attention to detail are out of this world. I will be both happy and sad when this build is done!


Funny my wife would like me to do the same thing with the build ;-)
Thank You!
Pat
Posted by: not_a_charger

Re: Modern Bullitt build - 02/03/16 09:50 AM

Cannot wait to see the finished product. This is one of the best threads Moparts has ever had, and the car is certainly going to be one of the nicest anywhere.
Posted by: Keepat

Re: Modern Bullitt build - 02/03/16 03:01 PM

Originally Posted By not_a_charger
Cannot wait to see the finished product. This is one of the best threads Moparts has ever had, and the car is certainly going to be one of the nicest anywhere.


Thank you sir!!!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 02/03/16 03:02 PM

Fitted and welded the last torque box (left front) next up is welding the unused holes in the firewall.
Thanks
Pat










Posted by: Keepat

Re: Modern Bullitt build - 02/06/16 09:53 AM

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











Posted by: Hooligan

Re: Modern Bullitt build - 02/06/16 01:34 PM

AMAZING work and imagination! What planet are you from???
Posted by: Keepat

Re: Modern Bullitt build - 02/06/16 02:20 PM

Originally Posted By Hooligan
AMAZING work and imagination! What planet are you from???


LOL, I'm pretty sure earth but some of my friends think it's planet Uranus ;-)
Thank you!
Pat
Posted by: Bullitt Guy

Re: Modern Bullitt build - 02/16/16 03:39 PM

Pat

what grit sanding discs are you using to get that bare metal look after welding?

Paul
Posted by: Keepat

Re: Modern Bullitt build - 02/17/16 12:30 PM

Originally Posted By Bullitt Guy
Pat

what grit sanding discs are you using to get that bare metal look after welding?

Paul


Paul,
I finish up with 80 grit paper on DA, I'll try to do is a little better pictorial of the process from raw weld to finish panel in the next couple weeks.
Thanks
Pat

PS. Cool screening Name!
Posted by: hotairballoonpilot

Re: Modern Bullitt build - 02/17/16 01:43 PM


Where did you get that long vipe grip clamp? That could come in REALLY handy at times!


Originally Posted By Keepat
I started on the driveshaft loop/crossmember today. Using a press I oval a 2” section of 6” pipe and hammered the top half to match the shape of the driveshaft tunnel. With the loop clamped in place and using a 15” contour gauge (a must have tool) I made two cardboard pattern for the crossmember. With the cardboard center section of each pattern as wide as the square tubing (2”) I was able to lay it over the tubing to get a precise line to cut with the plasma cutter. I still need to make the pattern for inside the tunnel above the loop before I can weld it to the floor.
Thanks
Pat


























Posted by: Keepat

Re: Modern Bullitt build - 02/17/16 03:40 PM


It is an awesome clamp that I purchased from a supplier at one of the Carlisle events. It's one of those tools that you don't use a lot but when you need it nothing else will work as good. Below is a link for the company that sells them.
Thanks
Pat

http://www.stronghandtools.com/stronghandtools/products/longreach.php
Posted by: hotairballoonpilot

Re: Modern Bullitt build - 02/18/16 01:06 PM

thanks!
Posted by: Keepat

Re: Modern Bullitt build - 02/20/16 05:40 PM

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











Posted by: Keepat

Re: Modern Bullitt build - 02/21/16 04:46 PM

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.



Posted by: Keepat

Re: Modern Bullitt build - 02/21/16 04:53 PM









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
Posted by: Jalaska907

Re: Modern Bullitt build - 02/25/16 01:03 AM

Hey there! First off, I just want to say thank you for the build thread. Very impressive fabrication skills. I do have a question though, I was wondering what thickness metal you use for body panel repair, and metal thickness for the sheet metal work your doing? Thanks, looking foreword to watching this build.

Justin
Posted by: Keepat

Re: Modern Bullitt build - 02/25/16 05:25 PM

Originally Posted By Jalaska907
Hey there! First off, I just want to say thank you for the build thread. Very impressive fabrication skills. I do have a question though, I was wondering what thickness metal you use for body panel repair, and metal thickness for the sheet metal work your doing? Thanks, looking foreword to watching this build.

Justin


Justin,
All of the body panels I have matched the same 20 gauge steel that was used originally. For most of the structural components that I added to the bottom of the car I used 14 gauge to 1/8" steel and some 3/16". Thanks for following along!
Pat
Posted by: sparcy

Re: Modern Bullitt build - 02/25/16 09:11 PM

this build is one of my favorites .!!! you and the srt8 roadrunner guy are over the top !!! I use the info from both of you !! your welding skills are so impressive !! THANKYOU !!!
Posted by: Keepat

Re: Modern Bullitt build - 02/26/16 08:23 AM

Originally Posted By sparcy
this build is one of my favorites .!!! you and the srt8 roadrunner guy are over the top !!! I use the info from both of you !! your welding skills are so impressive !! THANKYOU !!!


The community of car guys sharing ideas and techniques is what makes these forums so cool!
Thank you!
Pat
Posted by: larry4406

Re: Modern Bullitt build - 02/27/16 08:57 AM

I like that drill extension for the wire brush. Who makes that and where to buy?

Excellent build!
Posted by: Keepat

Re: Modern Bullitt build - 02/27/16 09:58 PM

Originally Posted By larry4406
I like that drill extension for the wire brush. Who makes that and where to buy?

Excellent build!


Larry,

I'm not sure who makes the extension but I bought it Home Depot
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 02/28/16 08:31 PM

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














Posted by: Keepat

Re: Modern Bullitt build - 03/01/16 03:56 PM

I had a mold made of the front bumper guard mount so I could make a carbon-fiber version of it. The steel mount weighs about 6 lbs and the carbon-fiber replacement will weigh about 1 lbs. After I pull the 1st part I’ll post a few pictures and if anyone is interested I could make a few more? I think I will paint mine black to look original but they could be left clear to show the carbon-fiber if you like?
Thanks
Pat





Posted by: MuuMuu101

Re: Modern Bullitt build - 03/01/16 04:41 PM

You work with Carbon Fiber too!? What are you using for your molds? I have some vacuum bag material at home. I was planning on making some Carbon Fiber components for the Dart in the next couple of years.
Posted by: Keepat

Re: Modern Bullitt build - 03/01/16 04:58 PM

Originally Posted By MuuMuu101
You work with Carbon Fiber too!? What are you using for your molds? I have some vacuum bag material at home. I was planning on making some Carbon Fiber components for the Dart in the next couple of years.


Yes, working around yachts for over 35 years one can learn a few things along the way ;-) We have a large vacuum bag machine that is use to make the hardtop for our 55 Fleming. The green part in the pictures is the mold pulled from the original part.
Thanks
Pat
Posted by: MuuMuu101

Re: Modern Bullitt build - 03/01/16 07:10 PM

Originally Posted By Keepat
Originally Posted By MuuMuu101
You work with Carbon Fiber too!? What are you using for your molds? I have some vacuum bag material at home. I was planning on making some Carbon Fiber components for the Dart in the next couple of years.


Yes, working around yachts for over 35 years one can learn a few things along the way ;-) We have a large vacuum bag machine that is use to make the hardtop for our 55 Fleming. The green part in the pictures is the mold pulled from the original part.
Thanks
Pat


I'll look at it at home. I can't see pictures on my work computer. But very cool, regardless. My carbon fiber work was done in college not too long ago. I made body panels for a small off-roading car and created carbon fiber coupons for a test I did for my senior project.
Posted by: larry4406

Re: Modern Bullitt build - 03/04/16 06:02 AM

Originally Posted By Keepat
Originally Posted By larry4406
I like that drill extension for the wire brush. Who makes that and where to buy?

Excellent build!


Larry,

I'm not sure who makes the extension but I bought it Home Depot
Thanks
Pat


I looked at these yesterday at Home Depot - the ones they had have a "quick connect" hex type chuck vs a 3-jaw chuck. I would like one with a 3-jaw.
Posted by: Keepat

Re: Modern Bullitt build - 03/05/16 04:05 PM

The CF part is all sealed up, vacuum bag and going into the heater box for the next 24 hours at about 140°
Thanks
Pat



Posted by: Keepat

Re: Modern Bullitt build - 03/06/16 03:51 PM

Boxed in the upper core support, amazing how much stronger it is now. I think I could pick the car up from it! I will use it run and hide the wires for the fans, horns, AC, and lights.
Thanks
Pat








Made tool to roll the top edge of the core support right at 1”























[img]http://i949.photobucket.com/albums/...yw4z6.jpg[/img]
Posted by: Keepat

Re: Modern Bullitt build - 03/06/16 03:54 PM


Posted by: minivan

Re: Modern Bullitt build - 03/08/16 05:09 PM

Really like the boxed in upper... Hard to believe the difference from stock.....
Posted by: Keepat

Re: Modern Bullitt build - 03/19/16 04:25 PM

1st coat of primer on the engine bay and fender wells.
Thanks
Pat







Posted by: 69charger440_6pa

Re: Modern Bullitt build - 03/21/16 11:37 PM

That must be a nice feeling to see that primer
Posted by: larry4406

Re: Modern Bullitt build - 03/24/16 06:10 AM

Very nice! The boxed upper radiator support looks excellent.
Posted by: Keepat

Re: Modern Bullitt build - 03/25/16 01:11 AM

Originally Posted By 69charger440_6pa
That must be a nice feeling to see that primer


Yes it is nice to be working on the body work as I'm starting to see the end of this project
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 03/25/16 01:15 AM

Originally Posted By larry4406
Very nice! The boxed upper radiator support looks excellent.


Thanks Larry, I very happy with it and maybe one day US car tool will make the part for others?
Thanks again!
Pat
Posted by: josh7965

Re: Modern Bullitt build - 03/29/16 03:39 PM

Originally Posted By Keepat
Originally Posted By larry4406
Very nice! The boxed upper radiator support looks excellent.


Thanks Larry, I very happy with it and maybe one day US car tool will make the part for others?
Thanks again!
Pat


if they made one for an e body i would be a buyer. nice work the car looks great
Posted by: Keepat

Re: Modern Bullitt build - 03/29/16 05:27 PM

Received my restored dash and instrument panel from Auto instruments very happy with their workmanship and the re-plastic plating.
Thanks
Pat







Posted by: Keepat

Re: Modern Bullitt build - 03/29/16 05:47 PM

Originally Posted By josh7965
Originally Posted By Keepat
Originally Posted By larry4406
Very nice! The boxed upper radiator support looks excellent.


Thanks Larry, I very happy with it and maybe one day US car tool will make the part for others?
Thanks again!
Pat


if they made one for an e body i would be a buyer. nice work the car looks great


Josh, I reached out to US cart tool and suggested they should manufacture this part, you should also do the same thing as it might motivate them to start making it for both E and B body Mopar's
Thank you
Pat
Posted by: Keepat

Re: Modern Bullitt build - 04/03/16 01:30 PM

Removed all the paint and carpet glue from the floor, next is the inside of the firewall (fun!)
Thanks
Pat






Posted by: Keepat

Re: Modern Bullitt build - 04/21/16 09:53 PM

After a few failed attempts we finally came up with the correct formula to make the bumper guard crossmember. We were having problems with the carbon fiber bunching up on top of the mold when in the vacuum bag. The carbon fiber on the mold side look excellent so we decided to hand lay a final layer of carbon fiber on the top side after it was removed from the mold. I'm not sure if I'm going to go with the carbon fiber look or if I'm going to end up painting it black so it would be undetectable. The steel crossmember is about 6 pounds and I ended up with the carbon fiber weighing in at 1 lb. 4 oz.
Thanks
Pat









Posted by: 69Cuda340S

Re: Modern Bullitt build - 05/01/16 07:37 PM

Outstanding work! Looking forward to more progress pictures.
Posted by: Keepat

Re: Modern Bullitt build - 05/02/16 12:51 PM

Originally Posted By 69Cuda340S
Outstanding work! Looking forward to more progress pictures.


Bill, Thank You! There is progress just nothing photogenic.
Pat
Posted by: Keepat

Re: Modern Bullitt build - 05/05/16 06:44 PM


Epoxy primer the bottom and engine well today.
Thank you!
Pat













Posted by: Keepat

Re: Modern Bullitt build - 05/15/16 05:23 PM

I started on the roof of the car by using paint stripper to remove the vinyl top glue, paint, and primer. Then I used a 6” DA sander to remove any leftover glue and paint. As with most vinyl top I was left with some rust and pitting to treat and repair. I coated the roof with a gel rust dissolver and covered the roof with plastic to keep the gel from evaporating. After about 8 hours I removed the plastic and rust dissolver then neutralize the roof with water, and paint prep. One last sanding with 80 grit on the DA sander, a wipe down with Final Klean and 2 coats of epoxy primer. Next I’ll will skim-coat the roof, sand and more epoxy primer.
Thanks
Pat



















Posted by: Keepat

Re: Modern Bullitt build - 05/22/16 01:03 PM

I used a Dremel with a wire brush to scuff the pits, and then block sanded the roof before skim coating it with body filler. Block sanded it again and sprayed a coat of high build primer. FUN! :-(
Thanks
Pat







Posted by: Keepat

Re: Modern Bullitt build - 06/05/16 01:46 PM

Started to see a little surface rust starting on the hood and trunk that I had soda blasted over a year ago and never epoxy primer. So I pulled them out and power wash them with a solution of Hold Tight which neutralizes and cleans off the excess soda on the bare metal. Then I sanded the panels with 80 grit paper with the DA sander. Before priming the outside I sprayed inside of the frame work with rust encapsulator/frame coating.
Thanks
Pat











Here you can see the left side in the picture is sanded and the right side is the virgin metal after powder coating.







Using Eastwoods internal frame coating and rust encapsulator I was able to spray inside both the trunk and hood framework in a variety of different positions to coat all the internal surfaces.







Posted by: Keepat

Re: Modern Bullitt build - 06/18/16 08:20 PM

After removing the sound deadening held up with contact cement I was able to prep and prime the inside of the roof. Before spraying the epoxy primer and coated the inside of the roof framing with a rust encapsulator.
Thanks
Pat










Posted by: Keepat

Re: Modern Bullitt build - 06/18/16 08:47 PM

Then I prep and sprayed the floors and package tray. Next I’ll seam seal the floor.
Thanks
Pat











Posted by: larry4406

Re: Modern Bullitt build - 06/19/16 07:43 AM

Very nice!

What brand of epoxy are your spraying (SPI)?
Posted by: Keepat

Re: Modern Bullitt build - 06/19/16 08:29 AM

Larry,
I'm spraying DuPont 2590S epoxy primer/sealer. Easy to mix and spray and lay down great!
Thank You!
Pat
Posted by: MattW

Re: Modern Bullitt build - 06/21/16 06:23 PM

I've been lurking around for awhile and I must say that your are the definition of hot rodding!
I am at a point where I'm thinking of pulling the plug on putting my paper weight together. Then I come here and you give me the bug again to finish it.
Thanks for the information on your build. You have inspired and educated me.
Matt
Posted by: Keepat

Re: Modern Bullitt build - 06/21/16 10:46 PM

Originally Posted By MattW
I've been lurking around for awhile and I must say that your are the definition of hot rodding!
I am at a point where I'm thinking of pulling the plug on putting my paper weight together. Then I come here and you give me the bug again to finish it.
Thanks for the information on your build. You have inspired and educated me.
Matt


Matt,
Thank you for your kind words, comments like yours inspire me to post the build.
Thanks again, now get out in the garage and finish your project ;-)
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/02/16 02:14 PM

Cleaned and painted the inside of the cowl and painted inside firewall along with the bottom of the Cowl. I use a paint that looks like the color of steel as this will make it a little brighter under the dash when working on it. With the car on the rotisserie it was very easy to use a self leveling seem sealer fill the original firewall panel seams.
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 07/03/16 10:44 AM

Using some cardboard I mocked up the rear brake cooling vents. I will make these up using .065 aluminum and have them powder coated black. I will make up the discharge side at the brake when the rear and wheels are back on.
Thanks
Pat








Posted by: 71rm23

Re: Modern Bullitt build - 07/03/16 05:02 PM

I just came across this build. I must be slow or something. Anyway, all I can say is WOW! I went through EVERY page. I'm blown away
Posted by: Keepat

Re: Modern Bullitt build - 07/03/16 07:14 PM

Originally Posted By 71rm23
I just came across this build. I must be slow or something. Anyway, all I can say is WOW! I went through EVERY page. I'm blown away


I'm slow also, been working on his car for over two years and I think I have another year to go ;-) thanks for checking out the build.
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/07/16 08:52 PM


I made the aluminum rear brake vents using my cardboard template. After welding them together and grinding most of the welds down I used a air tool with a medium Scotch-Brite pad to finish off and smooth out the welds. The Scotch-Brite pad is very user friendly and fast when working with aluminum.
Thanks
Pat


















Posted by: HUSTLESTUFF

Re: Modern Bullitt build - 07/11/16 07:33 AM

I think a NACA Duct in the torque box would do the same and belly pan the bottom of the car. Mike
Posted by: Keepat

Re: Modern Bullitt build - 07/11/16 12:28 PM

Originally Posted By HUSTLESTUFF
I think a NACA Duct in the torque box would do the same and belly pan the bottom of the car. Mike


A duct in the bottom of the torque box would work great with a belly pan. But I'm not planing on putting a belly pan on this car. Hard to see and fix problems on a street car
Thanks
Pat
Posted by: UCUDANT

Re: Modern Bullitt build - 07/11/16 10:56 PM

Wow, you do some outstanding/thorough work.
Posted by: Keepat

Re: Modern Bullitt build - 07/12/16 07:06 PM

Originally Posted By UCUDANT
Wow, you do some outstanding/thorough work.


Thank you, it my therapy, but I think a psychiatrist would be cheaper ;-)
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/17/16 05:30 PM


Not a productive weekend on the charger as I went to Carlisle, but I did spray some hi build primer on the hood and trunk lid today.
Thanks
Pat

Posted by: rhamson

Re: Modern Bullitt build - 07/28/16 02:12 PM

Looking good Pat. Keep up the good work.
Posted by: Keepat

Re: Modern Bullitt build - 07/30/16 06:15 PM

Originally Posted By rhamson
Looking good Pat. Keep up the good work.



Hi Ralph, I hope you are well! How is your Challenger project?
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/31/16 02:58 PM

Finally I have removed all of the original paint and primer except for A small section at the center rear valance. She's all prepped and ready for epoxy primer just need the shop to cool off a little.








Posted by: gch

Re: Modern Bullitt build - 07/31/16 04:16 PM

I admire you patience,dedication,and skills.
Posted by: Keepat

Re: Modern Bullitt build - 07/31/16 07:28 PM

Originally Posted By gch
I admire you patience,dedication,and skills.


49 % Patience, 49 % dedication, 2 % skills ;-)
Thank you
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/31/16 07:29 PM

All primed!











Posted by: Keepat

Re: Modern Bullitt build - 08/05/16 03:45 PM

With the car completely epoxy primed I applied all the seam sealer on the exterior panels, starting with the roof drip rail. After sanding with 220 and a Scotch-Brite pad, l taped both the drip rail and roof to control the edge of the seam sealer. Using a product from 3M called Fast & firm #08505 I tooled it in using my finger and little lacquer thinner to keep i pliable. This Fast & Firm is easy to use and works great for paint or a vinyl top. I saved a small section of the original seem sealer to maintain the same shape.
Thanks
Pat













Posted by: Keepat

Re: Modern Bullitt build - 08/18/16 04:22 PM

Not much to show the last two weeks as I've been out of town but I did get some more some seam sealer done around the trunk and quarters.
Thanks
Pat











Posted by: 69Cuda340S

Re: Modern Bullitt build - 08/19/16 06:47 AM

Awesome work!
Posted by: Keepat

Re: Modern Bullitt build - 08/19/16 01:59 PM

Originally Posted By 69Cuda340S
Awesome work!


Thank you sir!
Pat
Posted by: Hemi Allstate

Re: Modern Bullitt build - 08/19/16 10:33 PM


I agree!
Very nice work!
Mark
Posted by: rhamson

Re: Modern Bullitt build - 08/22/16 01:33 PM

Prepping the interior, jambs, engine compartment and trunk for finish paint before I get her off of the rotisserie. So many details and forgotten pet peeves I am tidying up along the way. It is just as well as the weather is lightening up with the humidity to paint. I am also collecting the suspension parts for the wheels to be mounted.
Posted by: rhamson

Re: Modern Bullitt build - 08/22/16 01:35 PM

Looking good Pat!
Posted by: Keepat

Re: Modern Bullitt build - 08/23/16 08:47 AM

Originally Posted By Hemi Allstate

I agree!
Very nice work!
Mark


Thanks Mark!
Posted by: Keepat

Re: Modern Bullitt build - 08/23/16 08:56 AM

Originally Posted By rhamson
Prepping the interior, jambs, engine compartment and trunk for finish paint before I get her off of the rotisserie. So many details and forgotten pet peeves I am tidying up along the way. It is just as well as the weather is lightening up with the humidity to paint. I am also collecting the suspension parts for the wheels to be mounted.


Ralph, good to hear you are making progress on your car. Alex and I were talking about driving over to see you in his/your old Challenger soon!
Thanks
Pat
Posted by: MattW

Re: Modern Bullitt build - 08/26/16 09:03 AM

Originally Posted By Keepat
Originally Posted By 71rm23
I just came across this build. I must be slow or something. Anyway, all I can say is WOW! I went through EVERY page. I'm blown away


I'm slow also, been working on his car for over two years and I think I have another year to go ;-) thanks for checking out the build.
Pat


I'm in the same boat. As a matter of fact my boat is still in storage! Lol
Pat I have a question for you. Do you get more satisfaction from doing the project or from driving it?
I get more from fixing things that enjoying them?
I could easily GET my car finished but then I think what do I do when Its done?
Anyways thanks for posting your progress.
Matt
Posted by: Keepat

Re: Modern Bullitt build - 08/26/16 01:24 PM

Originally Posted By MattW
Originally Posted By Keepat
Originally Posted By 71rm23
I just came across this build. I must be slow or something. Anyway, all I can say is WOW! I went through EVERY page. I'm blown away


I'm slow also, been working on his car for over two years and I think I have another year to go ;-) thanks for checking out the build.
Pat


I'm in the same boat. As a matter of fact my boat is still in storage! Lol
Pat I have a question for you. Do you get more satisfaction from doing the project or from driving it?
I get more from fixing things that enjoying them?
I could easily GET my car finished but then I think what do I do when Its done?
Anyways thanks for posting your progress.
Matt


Hi Matt,
I enjoy the parts hunt and build the most, along with the 1st drive. I also like to drive the cars I build cross country, but that's about it. As this car has less then a year to go I'm already looking for the next project which will be a 194? Woody wagon for my wife. She help me with my 1st full restoration of a 1964 GTO back in the mid 80's so it's time for her to get back in the garage to help with her woody ;-)
Thank you
Pat
Posted by: Superfreak

Re: Modern Bullitt build - 08/27/16 10:25 AM

Wow!!!!
You definitely have some great fabricating skills and looks to be top notch quality. This will be one cool looking charger when done.

Robert
Posted by: Keepat

Re: Modern Bullitt build - 08/27/16 07:12 PM

Originally Posted By Superfreak
Wow!!!!
You definitely have some great fabricating skills and looks to be top notch quality. This will be one cool looking charger when done.

Robert


Robert,

Thank you! but when will it be done??? I'm working on the 3rd year of what I thought would be a two year build ;-(
Pat
Posted by: Keepat

Re: Modern Bullitt build - 08/28/16 02:58 PM

Finished up 90% of the seam sealer including a lot of areas the factory did not do that I had to use a pick tool prior to priming to remove the stones, grease and grime from the past 50 years. The beige seam sealer is 3M's fast and firm #08505. Easy-to-use, you can smooth out with a wet finger and 2 hours later you can clean up any mistakes with a rag and lacquer thinner.








Posted by: 69charger440_6pa

Re: Modern Bullitt build - 08/30/16 07:58 PM

nicely done
Posted by: Keepat

Re: Modern Bullitt build - 09/13/16 03:20 PM

I've been laid up for a few weeks with some hernia surgery but I use this downtime to work on modifying the woodgrain steering wheel for the car. I love the look of the woodgrain wheel but driving my silver charger it was never comfortable handling the steering wheel as it's so thin. So I decided to modify this wood wheel to have a much larger modern size grip. I did not want to enlarge the diameter of the wheel as there already a little large compared to modern cars so I moved the inner ring in by about 3/8 of an inch. To do this I had to cut the S/S inner ring at all three spokes and weld it smaller in diameter and then Cut a new slot in all three spokes to hold the ring in its new location. While I have the steering wheel out for re-plating the spokes I need to brainstorm how I'm going to remake the larger plastic wood grain handle??? Suggestions welcomed!
Thanks
Pat
















Posted by: rhamson

Re: Modern Bullitt build - 09/17/16 08:28 AM

Sounds great. Just let me know when you guys plan on coming over. I would love to see my/his old car all done. I am now trying to get my car into the frame shop. The front rail is bent about 3/4" out of level. I have it off of the rotisserie and on it's wheels. I have also painted the interior and jambs to start hanging the sheet metal as soon as the frame is straight.
Posted by: Keepat

Re: Modern Bullitt build - 10/08/16 01:59 PM

Still making progress just not a lot of photogenic things show. A lot of boring sanding to prep the bottom and engine well for base-coat clear-coat.
Thanks
Pat






Posted by: Keepat

Re: Modern Bullitt build - 11/08/16 07:09 PM

Indy used pictures and specs of my motor in their on line add for the 6.1 :-)
click on the link and scroll to the bottom.
Pat


http://www.indyheads.com/6.1hemiengines.html
Posted by: Keepat

Re: Modern Bullitt build - 12/04/16 02:00 PM

Just starting to get back to work on the charger as I've been very busy at work. I did put some time in on the steering wheel project and I'm happy with my progress so far. I found another steering wheel with good chrome on the spokes. And I decided to leave small 1" sections of the original plastic wood grain in place to help position the outer ring as well as locate the inner ring that I made smaller in diameter. My plan was to use a product called West System which is a two-part epoxy that has a variety of fillers to help color, thicken, and add strength. I started by making a small mold of the shape I was looking for and just move it around using plumbers putty too damn up the ends when I filled it with a epoxy. This worked OK but didn't give me the results I was looking for so I decided to make a full mold. After using it to make the top half of the steering wheel I modified it to clear the spokes and used it again for the bottom half of the steering wheel. This worked great and other than a few air pockets which I can fill-in along with the holes that I drilled so I could use a syringe to inject epoxy into the bottom of the mold I think it turned out great. I plan on making it a darker shade of brown and then comes the tedious part of replicating the wood grain.
Thanks
Pat







This is a picture of the partial mold that I started using











Here's the mold has been waxed and filled with epoxy








First pull of the new mold




Then I cut the mold to clear the spokes and flip the steering wheel to redo the shape on the backside of the steering wheel.








[img]http://i949.photobucket.com/albums/ad340/kurts68fastback/image_zps5dorh8i1.jpeg[/img]
Posted by: 69Cuda340S

Re: Modern Bullitt build - 12/10/16 08:53 AM

Wow that steering wheel looks great!
Posted by: Keepat

Re: Modern Bullitt build - 12/11/16 07:39 AM

It's getting there, we'll see how good it looks after I'm done with fake wood grain.
Thank you
Pat
Posted by: coronet69

Re: Modern Bullitt build - 12/15/16 04:05 AM

wow i have read from 1 to 19 at a stretch yesterday

really good work!

what tool do you use to cut the metal, to cut a small pcs from a frame
Posted by: Keepat

Re: Modern Bullitt build - 12/16/16 01:52 PM

Originally Posted By coronet69
wow i have read from 1 to 19 at a stretch yesterday

really good work!

what tool do you use to cut the metal, to cut a small pcs from a frame




19 pages in 1 day, you must have been bored ;-)

For cutting metal a Plasma cutter works great with a guide and I also use a small Dremmel tool.

Thank you & welcome to the site!
Pat
Posted by: coronet69

Re: Modern Bullitt build - 12/17/16 10:53 AM

Home with the flu frown
Have some holes I have to fix on my coronet, maybe i have to buy a plasma cutter... there are cheap ones at aliexpress for about $200, But Im not sure if it will work?
Posted by: Keepat

Re: Modern Bullitt build - 12/21/16 10:11 PM

40+ hours and the steering wheel is just about finished. With a lot of sanding and adding more epoxy I got the oval shape I was looking for. Then I used a hook blade to add the wood grain affect. For color I used wood stain to darken the wood grain cuts and to get the color I was looking for.
Thanks
Pat















This is the difference in size and shape from the original steering wheel grip to the new larger oval.


Posted by: mopar4don

Re: Modern Bullitt build - 12/22/16 07:23 AM

Beautiful job Pat!
Posted by: 70B5Cuda

Re: Modern Bullitt build - 12/22/16 10:41 AM

Ridiculously cool work...
Posted by: Keepat

Re: Modern Bullitt build - 12/22/16 12:53 PM

Originally Posted By mopar4don
Beautiful job Pat!




Thanks Don and Merry Christmas to you and yours!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 12/22/16 12:53 PM

Originally Posted By 70B5Cuda
Ridiculously cool work...


Thank you sir!
Pat
Posted by: MoparCar

Re: Modern Bullitt build - 12/22/16 09:33 PM

What an awesome build and talent you have!!!

Thanks for sharing!

Wes
Posted by: NV69B7RR

Re: Modern Bullitt build - 12/23/16 01:34 PM

Wow, just wow!! To say your level of detail is amazing would be an understatement! That wheel is over the top and something that I can say I have never really seen most restorers tackle themselves. I can't wait to see updates on this build. You have a talent that few builders do, keep up the beautiful work!
Posted by: Keepat

Re: Modern Bullitt build - 12/23/16 09:14 PM

Originally Posted By NV69B7RR
Wow, just wow!! To say your level of detail is amazing would be an understatement! That wheel is over the top and something that I can say I have never really seen most restorers tackle themselves. I can't wait to see updates on this build. You have a talent that few builders do, keep up the beautiful work!


I'm not to sure about talent, more like rocks in my head ;-)
Thank you!
Pat
Posted by: Superfreak

Re: Modern Bullitt build - 12/31/16 10:51 PM

Nicely done!
Posted by: Keepat

Re: Modern Bullitt build - 01/09/17 08:53 AM

Reassemble my home made paint booth over the weekend. I used boat shrink wrap for the walls and ceilings.





These two walls can roll up to get the car in and out.




Four 20x20x4 intake filters.






Window box holds two 20x20 fans and track for quick change 20x25x1 discharge filters.







A little clean up and the paint booth will be ready. This will be the 3rd car to be painted in this home made booth.
Thanks
Pat
Posted by: MoparCar

Re: Modern Bullitt build - 01/09/17 11:47 AM

Great build and booth! What are you using for a fan and is it a positive or negative pressure booth?

Thanks Wes
Posted by: Keepat

Re: Modern Bullitt build - 01/09/17 04:56 PM

Originally Posted By MoparCar
Great build and booth! What are you using for a fan and is it a positive or negative pressure booth?

Thanks Wes


Wes,

I'm using two 20 x 20" fans pulling the air out of the booth, with air in to the booth from the four large intake filters.
Thanks
Pat
Posted by: larry4406

Re: Modern Bullitt build - 01/09/17 06:21 PM

Pat - nice booth! I will have to steal some of this. Weather in the Washington DC area not real good now. What if anything you doing for heat?
Posted by: Keepat

Re: Modern Bullitt build - 01/09/17 07:18 PM

Larry,

The shop has 2 electric baseboard heater that keep the shop right around 60°, you can see one mounted just above the row of lights in the third picture above. Fortunately my shop rent includes the electric ;-)
Thank you
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/15/17 01:16 PM

Scored a nice 68 console Inland shifter on craigslist. My plan is to cut the base off and modify the shifter for my T 56 six speed using the T handle to engage a micro switch to operate the electronic reverse shut out on the T56
Thanks
Pat


Posted by: JERICOGTX

Re: Modern Bullitt build - 01/18/17 09:41 AM

I'm really looking forward to seeing this car, painted, and the assembly progress. yet, I'll be kinda bummed when it's all done. The detail, and seeing the work put into it, has been interesting. Keep up the good work.

BTW, you make me feel lazy LOL.
Posted by: minivan

Re: Modern Bullitt build - 01/18/17 02:25 PM

Originally Posted By JERICOGTX
I'm really looking forward to seeing this car, painted, and the assembly progress. yet, I'll be kinda bummed when it's all done. The detail, and seeing the work put into it, has been interesting. Keep up the good work.


My thoughts exactly... This car reminds me of a "riddler award" car.. So many hidden aspects to it...

I say this due to watching Chip Foose describe his "riddler" winning car one time... So many things you just don't realize until it is shown to you...
Posted by: Keepat

Re: Modern Bullitt build - 01/19/17 06:16 PM

Originally Posted By JERICOGTX
I'm really looking forward to seeing this car, painted, and the assembly progress. yet, I'll be kinda bummed when it's all done. The detail, and seeing the work put into it, has been interesting. Keep up the good work.

BTW, you make me feel lazy LOL.



Thank You sir!
Posted by: Keepat

Re: Modern Bullitt build - 01/19/17 06:17 PM

Originally Posted By minivan
Originally Posted By JERICOGTX
I'm really looking forward to seeing this car, painted, and the assembly progress. yet, I'll be kinda bummed when it's all done. The detail, and seeing the work put into it, has been interesting. Keep up the good work.


My thoughts exactly... This car reminds me of a "riddler award" car.. So many hidden aspects to it...

I say this due to watching Chip Foose describe his "riddler" winning car one time... So many things you just don't realize until it is shown to you...



Thank you!!
Pat
Posted by: Keepat

Re: Modern Bullitt build - 01/19/17 06:36 PM




I epoxy sealed, base coated, and cleared the bottom of the car today
Thank you!
Pat












Posted by: Keepat

Re: Modern Bullitt build - 02/19/17 08:27 PM



Landing gear is on and she will be on the ground soon. Then I'll hang the doors, fender, hood and trunk to set & correct the gaps.
Thanks
Pat






Posted by: rhamson

Re: Modern Bullitt build - 02/21/17 12:33 PM

Looking good Pat. Keep up the good work!
Posted by: Keepat

Re: Modern Bullitt build - 02/23/17 08:33 PM

Originally Posted By rhamson
Looking good Pat. Keep up the good work!


Thank you sir! FYI Alex bought a 1970 Cuda for his next project.
Pat
Posted by: rhamson

Re: Modern Bullitt build - 03/01/17 01:24 PM

Love Cuda's.
Posted by: Keepat

Re: Modern Bullitt build - 03/08/17 10:32 PM

Off the rotisserie and on four wheels ;-)
Thanks
Pat





Posted by: Keepat

Re: Modern Bullitt build - 03/11/17 06:25 PM

Had to do a little metal work on the passenger door before I could hang it.
Thanks
Pat














Posted by: Keepat

Re: Modern Bullitt build - 03/12/17 12:16 PM

The subject of small dings and dents was brought up, so I thought I would post a few pictures of how an old body man showed me an easy technique to work them out if you have access to the other side. Using a spring-loaded center punch with a filed down blunt end.

Start with locating and marking the dent from the backside. Then unscrew the spring-loaded center punch a few turns as to lessen the blow for the first try. It may take two or three strikes to get the panel flush, along with changing the tension on the spring loaded center punch. You may need to move the impact point a 16th of an inch in either direction to work the dent out.

Thanks
Pat

















Posted by: mopar4don

Re: Modern Bullitt build - 03/13/17 07:38 AM

Hey Nice tip Pat, And thank you for sharing.
Say what is that on the inside of the door? Something to cushion the blow of the center punch?
Posted by: Keepat

Re: Modern Bullitt build - 03/13/17 08:31 AM

Originally Posted By mopar4don
Hey Nice tip Pat, And thank you for sharing.
Say what is that on the inside of the door? Something to cushion the blow of the center punch?


Don,
That is just an optical illusion, I scraped away some of the sound deadening on the inside of the door so that the punch would make direct contact with the metal.
Thanks
Pat
Posted by: mopar4don

Re: Modern Bullitt build - 03/13/17 08:52 AM

Originally Posted By Keepat
Originally Posted By mopar4don
Hey Nice tip Pat, And thank you for sharing.
Say what is that on the inside of the door? Something to cushion the blow of the center punch?


Don,
That is just an optical illusion, I scraped away some of the sound deadening on the inside of the door so that the punch would make direct contact with the metal.
Thanks
Pat

Ahhh, I see it now!
Posted by: Keepat

Re: Modern Bullitt build - 03/14/17 09:22 AM

With the right side fender hung she is starting to look like a charger again :-)
Thanks
Pat



Posted by: jpilone

Re: Modern Bullitt build - 03/14/17 12:16 PM

Awesome work!! You should sell your services for the steering wheel!!
Posted by: Keepat

Re: Modern Bullitt build - 03/14/17 04:15 PM

Originally Posted By jpilone
Awesome work!! You should sell your services for the steering wheel!!


If I did that my hobby would become a job and I already have 1 job and not looking for another ;-)
Thanks
Pat
Posted by: mopar4don

Re: Modern Bullitt build - 03/14/17 04:19 PM

Originally Posted By Keepat
With the right side fender hung she is starting to look like a charger again :-)
Thanks
Pat

That is one FINE looking charger!
Posted by: Keepat

Re: Modern Bullitt build - 03/19/17 09:41 PM

Doors and fenders are closely aligned after a lot of massaging. Just need put the hood on and then I can start on the final gap alignment.
Thanks
Pat






Posted by: Keepat

Re: Modern Bullitt build - 03/21/17 11:10 PM

After a few small modifications to both front fenders I installed the front valance and the hood. The trunk lid is next and then I'll start fine-tuning all the gaps.
Thanks
Pat










Posted by: Bill_LBSR

Re: Modern Bullitt build - 03/24/17 08:33 PM

Your attention to detail and skills are impressive. This thread is motivation for me to finally start on my 69 charger project.
Posted by: Keepat

Re: Modern Bullitt build - 03/26/17 08:10 AM

Originally Posted By Bill_LBSR
Your attention to detail and skills are impressive. This thread is motivation for me to finally start on my 69 charger project.


Bill, Good to hear, I'll look foward to following your thread!
Thank You!
Pat
Posted by: MattW

Re: Modern Bullitt build - 03/26/17 05:12 PM

Nice work!!
You my friend have OCD!!! Would love to have you do my car.
Matt
Posted by: Keepat

Re: Modern Bullitt build - 03/27/17 08:52 PM

Originally Posted By MattW
Nice work!!
You my friend have OCD!!! Would love to have you do my car.
Matt


Matt,
I think most people on this site have OCD, Obsessive Chrysler Disorder ;-)
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 03/29/17 10:25 PM

Welded and filed the drivers door gaps. I set the sides at 5/32" leaving room for primer, sealer, base coat, and clearcoat. I had to weld a rod across the bottom of the door to close up the large factory gap that varied between 5/16" and 21/64. Now the bottom of the door is a consistent 7/32. Next up is the passenger door.
Thanks
Pat












Posted by: larry4406

Re: Modern Bullitt build - 03/30/17 06:27 AM

Excellent job Pat!
Posted by: mopar4don

Re: Modern Bullitt build - 03/30/17 04:24 PM

Nice job Pat. say do you have any pics show that rod from the inside of the door? I think I may have to do this to my car.
Posted by: Keepat

Re: Modern Bullitt build - 03/30/17 10:13 PM

Don, Here are a few pictures of the inside of the door.
Thank you
Pat





Posted by: larry4406

Re: Modern Bullitt build - 03/31/17 07:37 AM

Pat - what kind of rod is that and how did you weld it (TIG or MIG)? TIG rod?
Posted by: Keepat

Re: Modern Bullitt build - 03/31/17 08:46 AM

Larry, I used 1/8" tig welding rod (ER 70S-3)
Thank you
Pat
Posted by: mopar4don

Re: Modern Bullitt build - 03/31/17 09:46 AM

WOW, I cant even tell you did anything!
Awsome job! I will remember this when I get to the same point.
Thank you
Posted by: Keepat

Re: Modern Bullitt build - 04/06/17 10:17 PM

Passenger door gaps took a little more work. I had to add metal rod along the bottom edge and 1/2 of the front edge.
Thanks
Pat






















Posted by: larry4406

Re: Modern Bullitt build - 04/07/17 05:45 AM

Pat - are you using TIG or MIG welding?
Posted by: mopar4don

Re: Modern Bullitt build - 04/07/17 07:53 AM

Amazing work Pat!
Thank you so much for sharing your hard work!
It gives guys like me incentive to keep working on our projects!

The rod you used (ER 70S-3), Is this the same as the mig wire you are using?
Not sure if it matters?
Don
Posted by: Keepat

Re: Modern Bullitt build - 04/07/17 07:32 PM

Originally Posted By larry4406
Pat - are you using TIG or MIG welding?


Larry, All Mig welding. I'm still in the practicing stages of Tig welding. Tig welding is sort of like playing drums, you use your hands and feet and when it's done right you make a cool sound. Right now my Tig welding sounds like a monkey playing the bongos ;-)
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 04/07/17 07:35 PM

Originally Posted By mopar4don
Amazing work Pat!
Thank you so much for sharing your hard work!
It gives guys like me incentive to keep working on our projects!

The rod you used (ER 70S-3), Is this the same as the mig wire you are using?
Not sure if it matters?
Don


Don,
Yes, same type of wire I use in my Mig welder, just a lot smaller.
Thank you
Pat
Posted by: larry4406

Re: Modern Bullitt build - 04/07/17 08:23 PM

Thanks Pat. I'm trying to learn MIG.
Posted by: Keepat

Re: Modern Bullitt build - 05/28/17 10:58 PM

Still working on the bodywork but took a little break from the block sanding and made a filler between the grill mount and radiator support. I borrowed the idea from another member. I need to weld a small plate around the hood latch and install a few fasteners before I paint it.
Thanks
Pat








Posted by: Keepat

Re: Modern Bullitt build - 05/30/17 09:50 PM


I very happy with how it turned out with the hood latch plate welded in
Thanks.
Pat










Posted by: larry4406

Re: Modern Bullitt build - 05/31/17 06:10 AM

Very cool Pat!
Posted by: Keepat

Re: Modern Bullitt build - 06/01/17 06:01 PM

Originally Posted By larry4406
Very cool Pat!


Thanks Larry!
Pat
Posted by: jpilone

Re: Modern Bullitt build - 06/02/17 01:49 PM

I love that filler panel at the hood latch. Very clever!
Posted by: Keepat

Re: Modern Bullitt build - 06/11/17 10:19 AM

Originally Posted By jpilone
I love that filler panel at the hood latch. Very clever!


Thank you!


3rd and maybe final coat of primer on the hood and tops of both fenders? Very happy with all the gaps. This bodyworks part of the build sucks, I'm starting to get Popeye the sailor man forearm ;-)
We also have a new addition to the family :-)
Thanks
Pat












Santino "Sonny" Corleone
Posted by: larry4406

Re: Modern Bullitt build - 06/11/17 10:28 AM

Awesome gaps and pup!
Posted by: Keepat

Re: Modern Bullitt build - 06/13/17 12:31 PM


;-)


https://youtu.be/AsHOM1qn54M
Posted by: mopar4don

Re: Modern Bullitt build - 06/13/17 12:44 PM

Wow, you should make your charger into a rube goldberg machine!
Posted by: Keepat

Re: Modern Bullitt build - 06/13/17 06:03 PM

Originally Posted By mopar4don
Wow, you should make your charger into a rube goldberg machine!


Sometimes I feel like Rube Goldberg is working on it ;-)
Pat
Posted by: Keepat

Re: Modern Bullitt build - 06/25/17 07:39 PM

Mud work is done on the passenger side, and I sprayed 3 coats of high build primer now it's ready for some blocking sanding and another 3 coats of high build primer.
Thanks
Pat
















I was hoping to post an update but it looks like photobucket is holding all of my photos hostage for a $400 a year payment to use their so-called free site :-(
Posted by: Keepat

Re: Modern Bullitt build - 07/03/17 12:09 PM



<a href="https://postimg.org/image/g3wvn0ge1/" target="_blank"><img src="https://s20.postimg.org/g3wvn0ge1/IMG_8366.jpg" alt="IMG_8366"/></a>
Posted by: jpilone

Re: Modern Bullitt build - 07/03/17 01:40 PM

it says your photobucket account needs updating to allow 3rd party hosting.
Posted by: Keepat

Re: Modern Bullitt build - 07/03/17 09:24 PM

Originally Posted By jpilone
it says your photobucket account needs updating to allow 3rd party hosting.


Unfortunately photobucket has change their policy and is holding my photos hostage for a $400 a year fee. I'm not sure I'll be able to retrieve the photos but I will come up with a new program moving forward. Sorry
Pat
Posted by: larry4406

Re: Modern Bullitt build - 07/05/17 07:25 AM

Originally Posted By Keepat
Originally Posted By jpilone
it says your photobucket account needs updating to allow 3rd party hosting.


Unfortunately photobucket has change their policy and is holding my photos hostage for a $400 a year fee. I'm not sure I'll be able to retrieve the photos but I will come up with a new program moving forward. Sorry
Pat


Pat - I hope you have your photo's still saved somewhere else!. Love this thread and the work you are doing.

Lots of forums I frequent the posters have also gotten screwed by photobucket and the pics are lost.
Posted by: WyleECoyote

Re: Modern Bullitt build - 07/05/17 08:17 PM

Pat, et. al. - I motion to start a quasi "go fund me" account to pay the $400 for you for this year so you (and US) don't lose your photos! I've had intentions for month's to save all of your pictures and comments; so much valuable information you've shared with us.

I'll start with a $50 first donation. I can pay you through PayPal; send me a PM with your info.

What say you other members that love this thread!??

Let's pull together and make this happen!

Ron
Posted by: Keepat

Re: Modern Bullitt build - 07/06/17 09:00 PM

Originally Posted By WyleECoyote
Pat, et. al. - I motion to start a quasi "go fund me" account to pay the $400 for you for this year so you (and US) don't lose your photos! I've had intentions for month's to save all of your pictures and comments; so much valuable information you've shared with us.

I'll start with a $50 first donation. I can pay you through PayPal; send me a PM with your info.

What say you other members that love this thread!??

Let's pull together and make this happen!

Ron


Ron,

Thank you so much for the very generous offer! This is not about the money for me, it's all about an online company changing the rules and expecting people to pay and I'm just not going to do it. What's to keep them from upping the charge every year, so I'm not interested in participating in their greed.
Thank you
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/22/17 09:40 PM

With the bodywork close to being finished I started fitting the bumpers. Both ends needed to bent out a fraction to be parallel with the quarter panel. Then I cut about a 1/4" off of each side for a better fit. Paul's Chrome will de-chrome the bumpers and then finish the welding, they will also weld on the studs for the mounts.
Thanks
Pat











Right side before




Left side after


Posted by: larry4406

Re: Modern Bullitt build - 07/23/17 07:59 AM

Pat - the bumper mod looks nice!

Glad to see you posting again. This is my favorite build and I'm an ebody guy!

I wish I had saved your pictures of the upper radiator support bracing mod you did.
Posted by: Keepat

Re: Modern Bullitt build - 07/23/17 12:59 PM

Originally Posted By larry4406
Pat - the bumper mod looks nice!

Glad to see you posting again. This is my favorite build and I'm an ebody guy!

I wish I had saved your pictures of the upper radiator support bracing mod you did.


PM your email and I'll send you the upper radiator support pictures
Thanks
Pat
Posted by: Keepat

Re: Modern Bullitt build - 07/27/17 10:14 PM

The front bumper is now ready to head to the Paul's. Cut about 3/4 of an inch out of the front 3/8" from each side.
Thanks
Pat











Before




After




Before




After


Posted by: Keepat

Re: Modern Bullitt build - 07/30/17 03:56 PM

With moving the rear bumper tighter to the car I had to shave the bumper guards to fit the lower valance. Started by removing the lower mounting tab and grinding away approximately 3/16" on the bottom edge to clear the valance. Then welding the tab back on.
Thanks
Pat








Here you can see how much I needed to grind off





Posted by: Keepat

Re: Modern Bullitt build - 08/13/17 10:59 AM

Front valance required more work than the tail panel as there were a lot of factory imperfections. Someone also cut a couple of notches that required welding, just when I thought I was done with all the metalwork. Back to the block sanding :-(
Thanks
Pat










Posted by: Keepat

Re: Modern Bullitt build - 08/19/17 10:12 PM

I took a little break from the block sanding and bodywork and started making the aluminum front bumper brackets. Made a paper template of the driver side mounts and was very surprised when I flip the template inside out and it fit perfectly on the passenger side mounts. Need to do some welding and bend up the other 3 mounts.
Thanks
Pat






















Posted by: larry4406

Re: Modern Bullitt build - 08/20/17 08:47 AM

Nice job Pat!

What made you decide to go with aluminum brackets? Yours seem to be in excellent shape. Just wanting to shave a little bit of weight?
Posted by: Keepat

Re: Modern Bullitt build - 08/20/17 11:24 AM

Originally Posted By larry4406
Nice job Pat!

What made you decide to go with aluminum brackets? Yours seem to be in excellent shape. Just wanting to shave a little bit of weight?


Larry,

Yes all of my original mounts are in very good condition but I was just trying to cut more weight off the front of the car.
Thank you
Pat
Posted by: Keepat

Re: Modern Bullitt build - 08/20/17 06:07 PM


The right side mounts are bent, just need to be welded and then the welds ground down. I will test fit when the bumpers return from Paul's chrome before I paint the mounts, I'm sure they will need a little tweaking to fit.
Thanks
Pat












Posted by: cdstl

Re: Modern Bullitt build - 08/21/17 07:25 AM

How are you bending the aluminum?

thx
Posted by: Keepat

Re: Modern Bullitt build - 08/22/17 08:27 PM

Originally Posted By cdstl
How are you bending the aluminum?

thx


I'm using everything from vice grips to C clamps to a large vice, block of wood and a hammer ;-)
Thanks
Pat
Posted by: larry4406

Re: Modern Bullitt build - 08/23/17 08:23 PM

Originally Posted By Keepat
Originally Posted By cdstl
How are you bending the aluminum?

thx


I'm using everything from vice grips to C clamps to a large vice, block of wood and a hammer ;-)
Thanks
Pat


I sometimes resort to choice words as well..
Posted by: Scott Carl

Re: Modern Bullitt build - 08/25/17 12:20 PM

Love the fab work you're doing on bumpers. I drew the bumpers in on my 74 Challenger (Just another 74 Challenger thread) to make them more like earlier models. Rears were easy but fronts were a bit more of a challenge. (in-board ones hit frame rails when moved in) I hadn't considered just fabbing new ones so I chopped up stock ones wink Bumpers seem to fit well but after seeing your mods, I may revisit possible mods on mine before I finish. Blacking out mine (all black car)
Keep up good work. Would love to see earlier pics that are currently not viewable due to PhotoBucket issues. Cant wait to see final project!

Scott
Posted by: Keepat

Re: Modern Bullitt build - 08/27/17 01:04 PM

Originally Posted By Scott Carl
Love the fab work you're doing on bumpers. I drew the bumpers in on my 74 Challenger (Just another 74 Challenger thread) to make them more like earlier models. Rears were easy but fronts were a bit more of a challenge. (in-board ones hit frame rails when moved in) I hadn't considered just fabbing new ones so I chopped up stock ones wink Bumpers seem to fit well but after seeing your mods, I may revisit possible mods on mine before I finish. Blacking out mine (all black car)
Keep up good work. Would love to see earlier pics that are currently not viewable due to PhotoBucket issues. Cant wait to see final project!

Scott


Scott,
Photo Bucket screwed up a lot of Great threads on a lot of forums, very sore subject. I hope to follow up and replace the photos one day but it's just very time-consuming as you know. Thank you.
Pat
Posted by: Keepat

Re: Modern Bullitt build - 08/27/17 03:55 PM

More primer and block sanding ;-(
Pat








Posted by: Keepat

Re: Modern Bullitt build - 08/27/17 09:05 PM


Finished welding up the right side bumper mounts and ground down all the welds. When painted black I think it would hard to tell that they're not original.
Thanks
Pat












Posted by: cdstl

Re: Modern Bullitt build - 08/30/17 08:17 AM

How did you go about making the bends for your bumper mounts?

Thanks
Posted by: Keepat

Re: Modern Bullitt build - 09/03/17 02:02 PM


With a lot of brute force I managed to hit what I'm working on more often then my thumb ;-)
I hope these pictures help.
Pat











Posted by: cdstl

Re: Modern Bullitt build - 09/03/17 03:24 PM

Wow. Nice work
Posted by: Keepat

Re: Modern Bullitt build - 09/04/17 07:18 PM

Finished the bumper mounts, time to get back to block sanding and bodywork :-(
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 09/12/17 04:56 PM

Google chrome has a fix for the photobucket picture problem ;-)

https://chrome.google.com/webstore/d...fegnfnflicjjgj
Posted by: rhamson

Re: Modern Bullitt build - 09/13/17 09:31 AM

Looking good Pat. Are you going back to black?
Posted by: Keepat

Re: Modern Bullitt build - 09/13/17 08:41 PM

Originally Posted By rhamson
Looking good Pat. Are you going back to black?


Yes black with a black top just like the Bullitt Charger
Thanks
Pat
Posted by: dangina

Re: Modern Bullitt build - 09/14/17 10:41 AM

bravo on the aluminum brackets they turned out great!!!! its always been a mod I've wanted to do, and your way makes sense to me.
Posted by: Keepat

Re: Modern Bullitt build - 09/14/17 01:40 PM

Originally Posted By dangina
bravo on the aluminum brackets they turned out great!!!! its always been a mod I've wanted to do, and your way makes sense to me.


Thank you, I was very happy with how they turned out and I think when painted it will look very original
Thanks again
Pat
Posted by: Keepat

Re: Modern Bullitt build - 09/18/17 09:18 AM

Sprayed the last coat of primer on the car and ready for the 320 blocking
Thanks
Pat







Posted by: Keepat

Re: Modern Bullitt build - 09/18/17 06:25 PM

I used a level with a straight edge to help to find the center of the style line for laying out tape on the body line. When level, sliding the straight edge will leave a mark dead center of the body line. I'm sure there are many other ways of doing this but I found this work good for my old eyes ;-)
Thanks
Pat






Posted by: larry4406

Re: Modern Bullitt build - 09/19/17 06:05 AM

Pat - what is the purpose of the tape on the style line? A marker for sanding?
Posted by: Keepat

Re: Modern Bullitt build - 09/19/17 09:43 AM

Larry, Yes, the tape is used as a guide for block sanding as to keep a straight and true body line. After that top section is sanded I will tape just above the first tape line and then stand the next section.
Thanks
Pat
Posted by: larry4406

Re: Modern Bullitt build - 09/19/17 05:53 PM

Originally Posted By Keepat
Larry, Yes, the tape is used as a guide for block sanding as to keep a straight and true body line. After that top section is sanded I will tape just above the first tape line and then stand the next section.
Thanks
Pat

Very clever - I imagine this will make the style line quite sharp.
Posted by: Keepat

Re: Modern Bullitt build - 09/23/17 04:16 PM

With the body lines taped I blocked sanded the top 1/3 and bottom 1/3 of the sides with 320 grit sand paper. Then using the 1st tape line as a guide, I ran tape above or below the first tape line so I could block sand the center section of the car. This creates straight but sharp body lines that need softened. After removing all the tape I went back over both sides with 400 grit sand paper softening the body lines.
600 grit paper is next one step away from sealer :-)
Thanks
Pat







Posted by: paironines

Re: Modern Bullitt build - 09/24/17 10:57 AM

When you move the tape from the bottom of the body line to the top of the line, do you put it on the exact line as before or a 1/16 higher? You mentioned "just above". I figure on the exact line would make it real sharp and leaving a space wouldnt really be sanded. Thanks!
Posted by: Keepat

Re: Modern Bullitt build - 09/24/17 03:21 PM

Originally Posted By paironines
When you move the tape from the bottom of the body line to the top of the line, do you put it on the exact line as before or a 1/16 higher? You mentioned "just above". I figure on the exact line would make it real sharp and leaving a space wouldnt really be sanded. Thanks!


The two tape lines touch. With all of the block sanding completed I removed all the tape and sanded the entire panel with 400 grit paper to soften the body lines
I hope this helps
Thanks
Pat
Posted by: paironines

Re: Modern Bullitt build - 09/24/17 05:11 PM

The two tape lines touch. Yes Thank you.
Posted by: Keepat

Re: Modern Bullitt build - 09/28/17 06:55 PM

I had a few people ask what materials I was using for primer, filler and paint so I thought I would pass this information on here as well.

Starting with all the paint stripped I sprayed the bare metal with Cromax epoxy DTM primer #2599S (DuPont product). From there I used all Evercoat products for the filler and high build primer. Evercoat Rage ultra body filler #100125 was used for the first layer over the Cromax epoxy primer, except for any edges or corners I used Evercoat Everglass #100622 Next was a skim coat of Evercoat polyester glazing putty #100400.

With all the filler sanded to 220 I sprayed 2 layer of Evercoat Super build primer #100730. Block sanded that down with 220 grit paper and sprayed two coats of Evercoat Finish Sand #100738. Sounds like a broken record but I block sanded that back down again with 220 grit paper.

Then last two coats of Evercoat Finish Sand #100738 and started block standing at 320 then to 400 grit paper.

For the sealer, basecoat and clearcoat I will be using all PPG products.
I will use PPG's DP90LF epoxy primer sealer. Then PPG Omni basecoat. And then we will follow it up with PPG's DC4000 clearcoat.

Thanks
Pat
Posted by: JERICOGTX

Re: Modern Bullitt build - 09/30/17 08:18 AM

I feel better about my choice of primer now. I bought the same stuff.
Posted by: Mr T2U

Re: Modern Bullitt build - 09/30/17 10:17 AM

Originally Posted By Keepat


For the sealer, basecoat and clearcoat I will be using all PPG products.
I will use PPG's DP90LF epoxy primer sealer. Then PPG Omni basecoat. And then we will follow it up with PPG's DC4000 clearcoat.

Thanks
Pat


i am not questioning you with my comments. you know what you are doing. i have been lightly following your build on IMBOC. i was scrolling down and saw this thread in the main board.

you might want to think about using a better sealer. epoxy thinned out as a sealer tends to shrink after a few weeks. that's the chemical nature of epoxy. it starts out as a thermo-plastic product for the first 2 weeks. after the first 2 weeks it becomes a thermo-set product. during this transfer it will shrink giving your smooth paint some texture. this might be a good thing, because a smooth paint job with some light texture is almost impossible to do.
i have been using PPG epoxy since the 80's and have seen this happen a LOT.

i myself use the envirobase ECS sealer line now. this is hands down the best sealer i have ever used. the biggest problem with it is it must be sprayed with a really good spray gun due to the high solids of the product. and you shouldn't spray it over bare metal. i give bare spots a little spray with SXA 1031.

your choice of the 4000 clear coat is a good one. this is a high solid clear that holds a shine and is extremely durable. it is also bakes well.
i use EC 530, fast cure, and 550, slow cure, clear coat. management doesn't want to stock 2 different catalysts for the 2000, fast, and 4000, slow, clears or this is what i would use.
Posted by: Keepat

Re: Modern Bullitt build - 09/30/17 11:24 AM

Originally Posted By JERICOGTX
I feel better about my choice of primer now. I bought the same stuff.



I love using Evercoat primer very easy to sand and extremely easy to work with.

Pat



Mr T

Thank you for your comments. I will do a test spray out with this PPG epoxy as I have not used it before. I have only used DuPont products in the past but to get this particular shade of black I had to switch to PPG.
Thanks again
Pat
Posted by: Mr T2U

Re: Modern Bullitt build - 09/30/17 12:37 PM

i have been using PPG products since around 1982. i don't remember when i attended my first training class when i first started using DBU base coat clear coat system.
if you have any PPG questions pm me here or at IMBOC under the same name.
i have a 08 bullitt.



epoxy thinned out used as a sealer is really old tech, i used to use it over 20 years ago. but now just about any PPG 2K sealer would be a better choice because it will be designed as a sealer from the start epoxy wasn't designed as a sealer when it was developed
.
omni base coat works pretty good for what it is but DBC base coat would be a better choice. there is a activator, DX57, for it. it will give the base coat a little help cross linking to help it dry and cure faster. it will also help with durability helping the clear coat adhere better to the base coat. it will spray exactly the same as omni base coat and the same spray techniques are the same. just don't spray the last coats on to dry, the clear coat might de-laminate. omni will have the same problems.
there isn't a activator for omni base. as far as color if it can be made in omni they can make it in DBC.

again i am NOT criticizing your choices of products to use. what you have listed will work just fine. i just hate to see you put so much time and money into a project and have problems with it later on.
Posted by: Keepat

Re: Modern Bullitt build - 10/01/17 04:44 PM

Mr T
Thank you for your insight and your comments. I have already purchased the materials, not that I can't change? I have two very close friends that have also painted cars for well over 35 years and they're holding my hand through this process, as they have done with previous cars I have restored.
Again I appreciate you chiming in, always good to get another perspective.
Pat
Posted by: Keepat

Re: Modern Bullitt build - 10/07/17 06:32 PM

Ok, this is the 4th and it will be the last primer coat! The 3rd coat was very close but not for black.
Thanks
Pat






Posted by: GY3

Re: Modern Bullitt build - 10/11/17 03:57 PM

Can't wait to see it in black!
Posted by: Keepat

Re: Modern Bullitt build - 10/21/17 08:34 AM

Was out of town for a few days and while away a package from the gates of Valhalla all shiny and chrome was delivered (actually it was my bumpers from Paul's chrome ;-) I will test mount them this weekend to confirm the fit along with my new aluminum bumper mounts.
Thanks
Pat







Posted by: JERICOGTX

Re: Modern Bullitt build - 10/21/17 12:22 PM

Impressive!
Posted by: larry4406

Re: Modern Bullitt build - 10/22/17 08:47 AM

Awesome build! Can't wait to see it finished.

I downloaded the photobucket hack for chrome and can see all of the pictures now and saved my favorites.
Posted by: Keepat

Re: Modern Bullitt build - 10/22/17 12:58 PM

Originally Posted By larry4406
Awesome build! Can't wait to see it finished.

I downloaded the photobucket hack for chrome and can see all of the pictures now and saved my favorites.


Larry,
It's great that somebody found a way around the photo buckit block out! I glad you load it and can get all the photos
Thank you
Pat
Posted by: Keepat

Re: Modern Bullitt build - 10/22/17 12:59 PM

I was happy to find that my aluminum bumper brackets fit great and have no movement whatsoever. Not sure I would use the original bumper jack, but that was never going to happen anyway ;-)
Thanks
Pat

















Posted by: Keepat

Re: Modern Bullitt build - 10/26/17 09:00 PM

For the first time in over 3 years my Charger has moved! Only about 15' ;-) from one side of the shop to the other but it's definitely a big milestone. I will start to clean the paint booth to get it ready for painting. All the block sanding (600 grit) is finished. I just need to take the fenders, doors, hood, and trunk off and detail the jams.
Thanks
Pat











Posted by: Keepat

Re: Modern Bullitt build - 11/08/17 09:38 PM

All the body panels are removed, still need to do some detail sanding in the door jams. I also drilled the holes for the power windows in the doors as well as the jams
Thanks
Pat











Posted by: larry4406

Re: Modern Bullitt build - 11/09/17 06:53 PM

Pat - what is that power window cable management piece? Very nice.
Posted by: Keepat

Re: Modern Bullitt build - 11/12/17 08:13 PM

Originally Posted By larry4406
Pat - what is that power window cable management piece? Very nice.


I bought it from electric life but I can't seem to locate it on their website they may have discontinued it??
Thanks
Pat

https://www.electric-life.com/product-category/wire-looms/rubber-wire-looms/
Posted by: Keepat

Re: Modern Bullitt build - 11/16/17 08:22 AM



Larry,

Correction I bought the wire looms from New Relics see link below
Thanks
Pat

https://www.nu-relics.com/Conduit-s/188.htm
Posted by: larry4406

Re: Modern Bullitt build - 11/16/17 07:37 PM

Originally Posted By Keepat


Larry,

Correction I bought the wire looms from New Relics see link below
Thanks
Pat

https://www.nu-relics.com/Conduit-s/188.htm


Its funny but I noticed this week that they look near identical to the ones in my 2012 ford focus!
Posted by: Keepat

Re: Modern Bullitt build - 11/19/17 02:15 PM

Most everything is sanded inside and out to 600 grit. Just the bottom of the hood left to do :-)
Thanks
Pat