Moparts

My 68 Hemi Charger Project -a little different

Posted By: Keith Black®

My 68 Hemi Charger Project -a little different - 05/23/11 02:20 AM

I thought it was about time I posted some pictures on my 68 Charger project as Moparts has been a constant source of help and inspiration.
In the end I had to buy 3 cars (yes three cars) to get a good body worthy of the project here in Australia. I'll share the story as it goes along.
Here's a photo of the original Charger:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:21 AM

2

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:22 AM

3

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:24 AM

4

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:34 AM

5

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:34 AM

6

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:36 AM

Me test driving the car before it get's dismantled.!!

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:37 AM

8

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:39 AM

small amount of rust

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:41 AM

76,000 original miles ..hmmmm..

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:43 AM

11

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:44 AM

12

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:46 AM

so then the dismantling started...

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:51 AM

...

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Posted By: Anonymous

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:53 AM

Nice rug!
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:53 AM

..

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:55 AM

..ultra high output 318 (came with 2 batteries!)

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 02:55 AM

Quote:

Nice rug!


(was the best part up until I got the 2nd car!)
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:10 AM

..true shape of body starting (!) to showing itself

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:13 AM

.....

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:16 AM

..spaghetti

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:18 AM

live .40 hollow point rounds fell out of the rear seat.
nothing surprising me anymore at this stage.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:22 AM

Overall core for the car 1 out of a possible 10.
Presumably a R/T 440 car with retrofitted 318. However, the tag & VIN numbers didn't seem to compliment each other, coupled with the live bullets falling out of the car, the RUST it was all looking a bit grim. Fortunately most of the bits & pieces (window channels door mechanisms misc. parts were helpful. Did I mention rust ..?

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:24 AM

.. and of course the Flinestone Floor in the trunk:


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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:30 AM

..funny thing is I wasn't even looking (just scratching my head about what to do with the first care).. when I came across a 68 Charger body on ebay. The owner had two cars (a '70 as well). He purchased the '70 sight unseen from the US, imported the car and discovered the body was in very poor shape (kinda like mine sounds familiar). He then decided to by the rolling body shell of the 68, I think in a plan to build one good car.
As it worked out, the project was not right for him, potentially to time consuming & costly, so he decided to sell the cars. But only if BOTH cars were sold

So I purchased both, and managed to sell the two I didn't want keeping the stripped parts from the first car.

The '68 rolling shell was in EXCEPTIONAL condition! Minimal surface rust on floorpans and trunk floor etc. So I was very lucky. It is a 383 Auto, A/C car. All the numbers matched and there were no bullets.




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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:31 AM

,,

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:32 AM

,,.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:33 AM

,,.,

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:34 AM

,..,

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:34 AM

,.,,

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:36 AM

on the trailer. collecting my new purchase.


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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:56 AM

so then it was off for media blasting. to clean up the body & see what needed to be done.
turns out the body was in great shape, no major structural dings. Only 6 in. of body filler in the RH quarter.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:58 AM

;

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:58 AM

;.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 03:59 AM

;..

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:00 AM

;...

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:02 AM

Note the 6in thick filler on the quarter

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:03 AM

,,....

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:05 AM

,'

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:06 AM

underside is in top condition.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:20 AM

-

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:21 AM

--

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:23 AM

note to self: if you get the car media blasted make sure you tape up all the holes in the chassis otherwise you have to unstitch the car to clean it out. you will also experience small piles of media forming on the floor everytime the car is bumped or moves.


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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:25 AM

old front crossmember.VERY heavy.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:28 AM

..the Basic car, media blasted, etched., major panels bolted on. ready for panelwork & decisions on how I want the car to be

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 04:55 AM

At this stage I had a great shell and all the little parts which you could never get without a car. I will post some more pictures when I have some time of all the bodywork we completed to get it perfect & straight.
Posted By: Anonymous

Re: My 68 Hemi Charger Project -a little different - 05/23/11 05:42 AM

Great project and an awesome score on the second car for a starter.
Posted By: Mopar Grandpa

Re: My 68 Hemi Charger Project -a little different - 05/23/11 01:49 PM

Great car, the '68's are my favorite. I'd like to have one with a modern drive train and all the creature comforts. Wish you all the best with this restoration. What are your exterior and interior colors going to be and what engine are you planning to use?
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:00 PM

Quote:

Great car, the '68's are my favorite. I'd like to have one with a modern drive train and all the creature comforts. Wish you all the best with this restoration. What are your exterior and interior colors going to be and what engine are you planning to use?


thanks John. I'm about 10% of the way through posting pictures on this post. The car is already a long way ahead & close to paint. I'll post some samples of the chosen paint color shortly.
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:06 PM

..so ..the first part was to strengthen things up a bit: Torque Boxes & frame connectors:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:09 PM

>

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:10 PM

aluminium fixed to the inside of the roof has made it very rigid:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:11 PM

then the sail panels & filler panel..

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:13 PM

new pieces. all joins are lead filled.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:17 PM

then we unstitched the back of the car including valance, cleaned it all up, sealed it, & installed new valance.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:18 PM

->

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:19 PM

..and this is before we made another change...

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Posted By: Golden-Arm

Re: My 68 Hemi Charger Project -a little different - 05/23/11 10:37 PM

looking good. keep them coming!!
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:43 PM

next we replaced the rear quarters:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:46 PM

which mean't tidying up the portions of the side panels in the boot (replacing) and some repair work, then sealing it all up rust preventative etc.'

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:47 PM

03

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:48 PM

we also put new inner fenders in, and have used insert-nuts throughout the body so there aren't any rusty washers/nuts/clips around in the future..

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:50 PM

we filled the marker lights all corners:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:51 PM

-=

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:52 PM

//

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:53 PM

\

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:54 PM

\\

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/23/11 11:55 PM

)

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:03 AM

The rear wheel tyre combo required that I widen/deepen the rear wheel area to accommodate the tyres. They're 345/30x19 Michelin Pilot PS2's. 13" Budnik Ice rims.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:04 AM

other side

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:05 AM

rh wheel well:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:07 AM

lh side

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:10 AM

..modifications to trunk supports (..in progress here)

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:11 AM

lh support..

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:12 AM

..moved in the inner fender flush with the chassis rail:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:14 AM

what the wheel well looks like finished with wheel on:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 07:00 AM

next was the sills. we took them off cleaned & sealed everything up. new sills.:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 07:02 AM

other side:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:04 AM

new door hinges, we actually unstitched the plenum chamber and sealed it all up too:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:06 AM

..after fitting the front guards we decided they were in pretty cr%$ppy condition:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:07 AM

.>

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:09 AM

so new panels through the front:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:12 AM

new front valance
NOTE: we are moving the signal/indicator/park lights out 2 inches each side (i.e. widening them) and widening the centre relief slightly, so the intercoolers/radiator etc gets slightly more air, and to enhance the wide car low stance look.

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:13 AM

with the new hood on:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:16 AM

front of car assembled for fit.
as I have mentioned be used insert nuts and made sure everything fits without shims, so panels are under no stress they just fit/bolt into place, perfect consistent gaps all round (including allowance for paint thickness etc).

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:22 AM

..and this is how it looked before I started to make MORE changes, and sanding & primer etc....:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:23 AM

and I put 69 tail light panel in it (which I am sure I will be flamed for)


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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:28 AM

semi-final body prep 1

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:30 AM

.......2

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:31 AM

sanded, ready for primer..:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 08:55 AM

and another pic of the 69 rear

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Posted By: tippytoe

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:34 PM

Lookin sweet ! Keep the updates coming !
Posted By: jpilone

Re: My 68 Hemi Charger Project -a little different - 05/24/11 12:53 PM

Looking great! Are you having a shop do all the work? Or are you doing it through a shop/yourself/with friends?
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 02:24 PM

I am doing as much as I can myself. Although, the body work I have a great guy doing it here for me, he does a lot of show cars etc,. I'm no expert in bodywork, but feel much better /confident at the mechanical aspects of the build. Trying to do as much as I can myself.
Still tons of stuff to post!
Thanks for the support of everyone here on Moparts
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 10:04 PM

So it's on to the front suspension, steering, & brakes. Here my new K-Member arrives from MegaParts in the US. They turn RB K Members into Hemi ones but changing the engine mounts and adding a skid plate etc.
I also got the engine mount brackets from them.

Attached picture 6648947-1-FrontSusp-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 10:06 PM

after it arrived I had the K member blasted and powder coated, including the engine mount brackets (turns out we will be painting them so may have been a waste of time etc.) however here is is as I start to assemble it:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 10:15 PM

Here's the parts list for the front K Member (I'll cover brakes, etc. later):
> Firm Feel Stage 2 Power Steering Box
> Firm Feel 11/16 Tie Rods
> Firm Feel reinforced Lower Control Arms
> Firm Feel Greasable lower Control arm pivots & Poly Bushes (installed)
> Firm Feel 1.06 in Torsion Bars
> Magnum Force Double Adjustable Upper Control Arms
> QA1 Double Adjustable Front Shock Absorbers
> Firm Feel 1-1/4 in front Sway Bar Kit
> RMS Adjustable Front Strut Rods

I'll post some Pictures of the parts: LCA's

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 10:17 PM

front shocks:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 10:19 PM

another shot of K Member coming together:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 11:11 PM

assembled:

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 11:30 PM

In terms of braking, I was inspired by the brakes used on the 1968 (Poteet) Nascar Charger built by Steve Strope.
However, getting any information on this brake setup was impossible. not from anyone anywhere nor Wilwood. I had to do a lot of research & a lot of calls. Using that as a baseline I researched & came up with my own system which wasn't straightforward but I am really pleased with the setup.

I have 14.25 slotted/vented/drilled disc's on the front, with TC6R radial mount 6-piston calipers. These are the largest caliper made by Wilwood (SUV caliper):

Attached picture 6649049-2-FrontBrakes-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 11:36 PM

I chose the FatMan drop spindles to retain the geometry in the front suspension while lowering the car the 2 inches I wanted.
The Fatman spindles are a long way from ideal (but no alrernatives where available at the time I put it together). If I was doing this part again today I would go for the one-piece drop spindles from Magnum force even though are are cast, they are strong (the Fatman spindle is in effect made of 4 pieces - hardly ideal for important this component).
I may yet change these.
Anyway, I had to have custom caliper brackets made to fit the calipers as the whole setup is non-standard and a long way from any kit offered by Wilwood.

Attached picture 6649053-2-FrontBrakes-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 11:44 PM

the billet Aluminium hubs provided by Wilwood are a nice piece, however it was difficult getting hub seals to match the hub/spindle (nonetheless I found some & bought a few sets spares!).
Here's a shot of the hat/rotors together and safety wired. Discs obviously only rotate 1 direction so they have to be on the correct side.
We mounted the caliper bracket in a way that also has a large bolt going into the upper part of the spindle as added strength to that welded area.
I am still considering swapping the spindles for one-piece units which may mean new caliper brackets (arrggghh !!$$). That's why I haven't yet made dust shields to cover the exposed area at the centre of the hub.. which I plan to do.

Attached picture 6649060-2-FrontBrakes-8.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 11:48 PM

the brakes are massive.better shot of safety wiring:

Attached picture 6649070-2-FrontBrakes-7.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/24/11 11:57 PM

one aspects of the Wilwood hubs I didn't like was that the hub centre is tapered, not really providing adequate support for the wheel to register on. I didn't want all the wheel load to be carried by the wheel studs. Also the brake hat internal diameter didn't provide a solid register (was slightly too large) again leaving the wheel studs to do the locating work. I fixed this and had a internally tapered shrink fit register made.. you can see it in this picture . this is a solid register for the wheel & brake hat:

Attached picture 6649088-2-FrontBrakes-10.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:09 AM

front upper control arms etc with k-member in.:

Attached picture 6649100-3-Frontin-8.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:10 AM

with spindle & brake assemblies installed:

Attached picture 6649101-2-FrontBrakes-13.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:14 AM

with wheel & tyres on:
Fitted 19in- 275/30x19 -

FINAL wheel/tyre will be 275/50 x 18. There is just enough room inside an 18" rim for internal rim/caliper clearance & I prefer higher profile (thicker) tyre on the front.

Attached picture 6649104-3-Frontin-9.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:24 AM

installed #1

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:25 AM

installed #2

Attached picture 6649118-3-Frontin-4.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:27 AM

installed #3

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Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:33 AM

looks a bit dusty from this angle, but from inside the engine compartment (have tidied this up a great deal since). note new hood hinges. engine mounts are poly-lock Schumacher mounts.

Attached picture 6649133-4-EngineCom-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:45 AM

So there were a few "learnings" from the front suspension/steering/brakes exercise. My to do list on this is now:
1. Change the upper control arms & tie Rods for hotchkis parts (see pic's below)
2. Sell the MagnumForce upper control arms and FF tie rods.
3. replace the spindles with MF 2 in drop spindles and have brake caliper brackets altered/remade.
4. wheel tyre combo for front to change to 275/50x18.

then I'll be happy with the front end.a few mistakes made but you learn as you go. I never wanted to go for one of the front ends like alterkation or magnum force units (or XV thank goodness) as they just don't provide the end result I want.

Now to the rear end & suspension:...

Attached picture 6649153-1-FrontSusp-20.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 12:50 AM

..woops (5. make up hub dust/cover plates to bolt to inside of spindles)
Posted By: jrwoodjoe

Re: My 68 Hemi Charger Project -a little different - 05/25/11 01:00 AM

Darren, I love the work you are doing on your car. It's going to be a GREAT car when it's done.

Joe
Posted By: MuuMuu101

Re: My 68 Hemi Charger Project -a little different - 05/25/11 01:10 AM

I love this thread! Amazing Car. My Favorite Mopar too! I hope to do one in the future
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 06:27 AM

thanks guys, ...moving to the rear end of the car, my first thoughts were around a Dana 60 & leaf springs:

Attached picture 6649723-1-Axle-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 06:29 AM

here are the rear tyres: may have mentioned 345/30 ZR 19 Michelin Pilot PS2's. I had to import them.

Attached picture 6649725-1-RearTyres-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 06:48 AM

The axle/diff setup I ordered (ex USA) was a custom order:
> Moser (Dana) 60
> 3.73:1 Detroit Locker
> 35 spline alloy axles
> Forged 1350 yoke
> Moser Alloy Rear cover 356-T6
> Standard width
> Std 4.5 x 5 x 1/2 studs
> Ford axle housing ends and axle bearings

[the reason for this is that Wilwood have(had) VERY limited choices for Mopar rears. The Ford axle ends/housing opened up significant options for the rear brakes]

> Brakes: Wilwood 14 inch slotted vented drilled discs, hat/hub units incorporating internal park drum-brake assembly, 4-Piston calipers.

Attached picture 6649745-2-RearBrakes-8.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:01 AM

one of the unexpected problems was that Wilwood had changed the discs between when I ordered the front ones, and the rears. The rear discs came "e-Coated" in a black powdercoat type covering.
The front discs looked great, in a zinc/nickel wash type of finish. Now the rear discs didn't match,..wilwood were unable to help in any way saying all their discs where now like this.

Attached picture 6649753-2-RearBrakes-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:05 AM

fortunately , I went to my local coatings/electroplater expert and he had a solution. He dipped the discs & removed the coating then replicated the wash Wilwood had used on the front. Here's a pic of one installed & safety wired.

Attached picture 6649756-2-RearBrakes-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:21 AM

with the rear axle sorted my original plan was to go with the leaf spring setup.
I ordered custom Hemi springs from Detroit-Eaton, lowered 2 inches (which when they arrived turned out as if they were raised 2 inches ). In the process I had to move the springs inboard 3 inches using the MP spring relocation kit.

Attached picture 6649764-4-LeafSpring-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:22 AM

..which included Caltracs at the front:

Attached picture 6649766-4-LeafSpring-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:23 AM

and THEN something happened...... I discovered THIS:


Attached picture 6649768-6-Unlawful-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:24 AM

..and:

Attached picture 6649769-6-Unlawful-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:32 AM

I say.. I gotta get me one of 'em..



So, I get on the phone to Unlawful Racing, and Daren irons and the great folks send me one. Turns out I am the first person to get the new product
Anyway, it turns up and it is an awesome system , with outstanding workmanship
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:33 AM

so I get stuck into it. The springs, Caltracs, and QA1's on the rear I manage to sell. And we start undoing the spring relocation work... and fit the 4-link cradle into the car:

Attached picture 6649771-5-4Link-0.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:35 AM

re-do the chassis rail (stronger), and the old spring perches:

Attached picture 6649773-5-4Link-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:37 AM

&rh:

Attached picture 6649774-5-4Link-3.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:39 AM

4-link cradle in situ:

Attached picture 6649775-5-4Link-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:42 AM

then the rear brackets are (carefully) welded:

Attached picture 6649776-5-4Link-4.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:49 AM

here's how it looks with everything mocked up (at first attempt):


Attached picture 6649780-5-4Link-5.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:08 AM

setup 1

Attached picture 6649784-5-4Link-06.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:08 AM

setup 2

Attached picture 6649785-5-4Link-07.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:09 AM

setup 3

Attached picture 6649786-5-4Link-08.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:10 AM

setup 4

Attached picture 6649787-5-4Link-09.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:12 AM

setup 5

Attached picture 6649788-5-4Link-10.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:16 AM

setup 6

Attached picture 6649790-5-4link-11.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:17 AM

setup 7

Attached picture 6649791-5-4Link-12.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:19 AM

setup8

Attached picture 6649792-5-4Link-15.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:25 AM

clearances are close:

Attached picture 6649794-5-4Link-16.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:27 AM

installed "as is" (note all the space under the quarter now available

Attached picture 6649795-5-4Link-17xx.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:32 AM

whole system "as is":

Attached picture 6649797-5-4link-18.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/25/11 08:36 AM

NOW this is where it started to get a little tricky. This is the ride height I want. The car is lowered 2 inches all around.
I also wanted the full range of suspension travel without interference when lowered.
..

Attached picture 6649798-7-Car-5.jpg
Posted By: johnscudashop

Re: My 68 Hemi Charger Project -a little different - 05/25/11 11:40 AM

I love this project, keep up the good work.!!
Posted By: 19cuda73

Re: My 68 Hemi Charger Project -a little different - 05/25/11 07:15 PM

Darren Great looking project Keep the pictures coming.

Dennis
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 03:50 AM

thanks for the comments people

this is where it got interesting.. given the stance of the car, 2 in lowered, I ran into some suspension travel & interference issues. I wanted to retain the correct rear end geometry throughout the full range of travel, & no have any intereference. With the awesome help of the Irons' (given I am on the other side of the world!) we managed to achieve my goal through modifying the 4-link cradle, & lowering the lower shock points:

Attached picture 6655867-5-4Link-22.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 03:51 AM

lower shock mount modification:

Attached picture 6655868-5-4Link-23.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 03:58 AM

so the back of the car was looking good now. the unlawful system was spot on. through the whole range of travel the driveshaft only moves1/8 inch into/out of the transmission.

Next I'll move onto the transmission installation (T56 Magnum) & how we got it to fit.

PS:Still only a small way through all the pictures!

Attached picture 6655879-7-Car-8.jpg
Posted By: MuuMuu101

Re: My 68 Hemi Charger Project -a little different - 05/29/11 04:18 AM

I have a small favor to ask... When you're done with it, do you mind sending it down here to SoCal so that I could take it out for a spin? I would really appreciate it. JK
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 08:50 AM

too easy JK.
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:01 AM

So, I don't want to take too much mystery out of the engine combination but you'll see some pictures from here on. Note that the engine installed is not the final engine. Even though it is an aluminium Hemi, its not the final one. It will be an aluminium Hemi but not this block (it'll be a KB block instead of the world block shown.

So, it will be an injected, under-the-unaltered-standard-hood -Supercharged, twin-intercooled, aluminium Hemi, 525 cu.in. This is the power curve I am shooting for:

Attached picture 6656104-power-torque-simulation.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:03 AM

'nuf said.
Here's the block installed showing where the bellhousing/trans will be installed:

Attached picture 6656105-1-Eng-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:05 AM

other side2/2:

Attached picture 6656106-1-Eng-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:06 AM

engine/bulkhead clearance:

Attached picture 6656107-1-Eng-3.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:13 AM

Here is a picture of the T56 Magnum.Freshly unpacked. Nice
this one is P/N TUET8277.
Ratios:
1 2.97
2 2.07
3 1.43
4 1.00
5 .80
6 .63
R 3.28



Attached picture 6656113-2-T56-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:17 AM

Now, a problem! The RM6077 Quicktime Bellhousing has a flat mating surface where it mates to the transmission.
Turns out the T56 and T56 have different front housings. The T56 Magnum has bosses protruding from the front.
So I couldn't get it to bolt up. :


Attached picture 6656114-2-T56-4.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:19 AM

Quicktime were really helpful. Turns out the Bellhousing i have is older stock and all new bellhousings have relief's machined in them so they fit. All I had to do was machine some reliefs in the bell face (no reduction in strength).
Quicktime game me a CAD file if anyone's interested (it's attached).

Attached File
6656115-2-T56-8-RM6077.pdf  (173 downloads)
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:20 AM

here's some pictures of the exact machining I did (from some other websites):

Attached picture 6656116-2-T56-5.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:21 AM

finished bell:

Attached picture 6656117-2-T56-7.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:22 AM

and here it is bolted in (With some major sheetmetal removal from the transmission tunnel!)


Attached picture 6656118-2-T56-11.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:23 AM

anothershot:

Attached picture 6656119-2-T56-12.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:24 AM

new bell/firewall clearance:

Attached picture 6656120-2-T56-10.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:26 AM

another shot/T56 M in place:

Attached picture 6656121-2-T56-13.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:27 AM

inside the car- this is the impact on the trans tunnel--

Attached picture 6656122-2-T56-14.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:29 AM

transmission tunnel cut other side--

Attached picture 6656124-2-T56-15.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:31 AM

with old dash frame, steering column etc removed.
Note I patched the bulkhead as I will be running Vintage Air Gen IV climate system, will all be up/inside the dash frame.

Attached picture 6656126-3-Tunnel-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:33 AM

nest step bright purple cardboard to cut a template for new tunnel


Attached picture 6656127-3-Tunnel-10.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:34 AM

AND ..done:


Attached picture 6656128-3-Tunnel-12.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:35 AM

finished tunnel 2/2:

Attached picture 6656129-3-Tunnel-13.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:38 AM

here's a cheeky pic of something I'll provide more detail of later

yes that's an e-Body dash. We stitched a B & E body dash frame together... more to come on this later

Attached picture 6656130-3-Tunnel-16.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:40 AM

Ok, here's some of the strengthening made to support the x-member. The crossmember had to be cut to make room for the bulky transmission.
We made a higher support to keep the strength, this is VERY thick steel 1/4 in., and the lower/mount support ties it together very rigidly.

Attached picture 6656131-3-Tunnel-19.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:41 AM

here's first shot of lower mount, also made entirely out of 1/4in steel.

Attached picture 6656132-4-Mount-0.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:43 AM

and another of the mount fab:

Attached picture 6656133-4-Mount-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 09:47 AM

finished transmission install.
Angles perfect,
Note the Poly-lock trans mount & new Driveshaft.
Custom made:
Mark Williams Chrome Moly, 1350 Strange Billet Steel trans Yoke. Very Nice peice

I looked at fabricating a two-peice shaft with a centre bearing but the consensus was maintaining alignment with the centre bearing throughout the power & operating range would have caused failure. Torque will be huge, so not worth the risk.

Attached picture 6656134-4-Mount-2.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:06 AM

So I'll make a small detour here and show how the brake m/cyl & pedals are set up.
Here;s the master cylinder & Hydraboost system:

Attached picture 6656135-5-Pedal-0.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:08 AM

another pic of m/c

Attached picture 6656136-5-Pedal-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:10 AM

installed (incl. making a plate to mount to firewall):

Attached picture 6656137-5-Pedal-2.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:13 AM

Also installed the clutch m/cyl at this time. Made up a billet aluminium bracket to support the cylinder. Great kit, supplied by American Powertrain. Good to deal with. speedy.priced better than competitors.can order straight from website.


Attached picture 6656138-5-Pedal-6.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:14 AM

another of clutch m/c mounted:

Attached picture 6656139-5-Pedal-7.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:17 AM

The reconditioned pedal assembly (4-spd) I ordered from SMS Auto.
Great service there too.

Attached picture 6656140-5-Pedal-10.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:19 AM

(...that also included the park brake setup.)
Here's some closer pics. We modified the pedals for the clutch kit:

Attached picture 6656141-5-Pedal-9.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:22 AM

2/2. I have not finished this yet. I am still to make hard-stops for the pedals to prevent bottoming out the piston in the cylinder during bleeding or otherwise.

Attached picture 6656142-5-Pedal-8.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/29/11 10:27 AM

back on topic: So the driveline & angles are all set up now. NOW I decide the run the exhaust system.
Turns out this is no mean feat. The headers are 2-1/4 primaries (TTI) into 4 inch collectors. I take that down to 3-1/2 and eventually into 3 inch.

As it stands there is NO (zero) room to run 3 inch pipes over the differential... however NFW am I attempting to run this underneath the axle when I am already lowering the car 2 inches.





Attached picture 6656143-7-Car-3.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 12:51 PM

Starting from the front of the car and working back. Here are the new TTI Headers.
2-1/4 primaries into 4 inch collectors. I ordered the ceramic coated with thermal barrier & with oxygen sensor bungs.

Attached picture 6659129-1-Headers-0.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 12:53 PM

with the steering box removed, this is the starting position (not as much room as there seems)

Attached picture 6659131-1-Headers-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 12:56 PM

LH side headers installed (without steering box), note torsion bar clearance..

Attached picture 6659133-1-Headers-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 12:58 PM

another shot of installed clearance.
1.06 torsion bars + 2-1/4 primaries = clearancing required

Attached picture 6659135-1-Headers-3.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 12:59 PM

and from above:

Attached picture 6659136-1-Headers-4.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:01 PM

front of engine -pre install of steering box:

Attached picture 6659143-1-Headers-5.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:03 PM

to clear the steering box we had to move the front primary tube & reposition. very very tight clearances:

Attached picture 6659146-1-Headers-6.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:04 PM

closer picture of modification to tube:

Attached picture 6659149-1-Headers-7.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:07 PM

.... side shot of LH headers installed, nice & tight, not hanging down:

Attached picture 6659151-1-Headers-8.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:09 PM

RH side, ready for headers, looks more optimistic than LH side

Attached picture 6659155-1-Headers-20.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:10 PM

installed. clearances tight

Attached picture 6659158-1-Headers-21.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:12 PM

from top, RHS, valve cover close to shock:

Attached picture 6659159-1-Headers-22.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:14 PM

RHS primary pipes installed, picture from below, very close to torsion bar (we notched it):

Attached picture 6659162-1-Headers-23.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:15 PM

another;

Attached picture 6659165-1-Headers-24.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:16 PM

RHS header installed, from collector:

Attached picture 6659168-1-Headers-25.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:19 PM

headers installed, from under front of car:

Attached picture 6659172-1-Headers-30.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:21 PM

picture of headers from side:

Attached picture 6659174-1-Headers-31.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:24 PM

good ground clearance, headers are tight. very happy with the headers despite the modifications required to fit & the ceramic coating is a bit "B" grade but I am jet-hot-coating the whole system on final assembly anyway

Attached picture 6659181-1-Headers-36.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:28 PM

to the mid-section.
made our own x-pipe and all pipes for that matter, using mandrel bends, collectors are 4 inch down to 3 inch into Magnaflow mufflers.

There will be 4 mufflers....

Attached picture 6659189-2-Midsection-0.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:30 PM

x-pipe:

Attached picture 6659191-2-Midsection-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:31 PM

another, x-pipe, front part of system:

Attached picture 6659192-2-Midsection-2.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:34 PM

these are the v-clamps i used. they're a great part. stainless v-rings welded to pipe & clamped with an inverted v-clamp. this meant the system could be constructed in sections. easier later if i need to replace any individual part; .. big pipes

Attached picture 6659197-2-Midsection-3.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:36 PM

....& toward the rear:

Attached picture 6659199-2-Midsection-5.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/31/11 01:42 PM

fabricating the exhaust system was a major.
a HUGE job.
the TTI's are great, but given the tight clearances it's hard to expect they will fit out of the box. then getting 3 inch pipes down the car, with enough ground clearance considering the car is lowered 2 inches (a "true" 2in), was a challenge.
all before trying to get 3inch pipes over the diff, which the next pic;s show how we did it. HUGE job, but it turned out great...

(still many more pics to come..!)
Posted By: 70shaker6pk

Re: My 68 Hemi Charger Project -a little different - 05/31/11 08:15 PM

Very nice, great work!
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:16 PM

thanks Pete. been hard work, years and $$.
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:17 PM

Now, getting 3 inch pipes (mandrel bends) over the diff meant making a new axle-hump. Just simply not enough room.

Attached picture 6661021-3-Axle-0.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:19 PM

So we made sections with the same v-clamps:

Note: all pipes will be jet-hot-coated (ceramic) at final assembly.

Attached picture 6661025-3-Axle-1.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:21 PM

with the new axle-hump we fabricated enough room to put extra's underneath, such as fuel tank vent charcoal canister and output in-line filter (more later). New hump retains provisions for rear seat-belt anchor too:

Attached picture 6661027-3-Axle-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:22 PM

with the rear seat frame installed (slight mods to clear widened wheel wells): looks a bit scruffy but only a trial fit.:

Attached picture 6661038-3-Axle-3.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:24 PM

looking forward where the mid-section ends and goes over the diff:

Attached picture 6661044-3-Axle-4.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:25 PM

front, from rear axle:

Attached picture 6661047-3-Axle-5.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:29 PM

with the extra space created by removing the leaf springs, and going for the look I wanted, I put the second muffler (3 inch magnaflows), up into the lower quarter, pic 1:

Attached picture 6661056-4-Tailpipe-1.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:30 PM

they fit really well,:

Attached picture 6661058-4-Tailpipe-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:31 PM

..almost designed for 'em:

Attached picture 6661060-4-Tailpipe-5.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:32 PM

whole system installed:

Attached picture 6661062-4-Tailpipe-8.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:33 PM

couple more pics of the entire system installed, less tank:

Attached picture 6661064-7-Complete-1.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:34 PM

another,
+ brake lines, handbrake cable, wiring, fuel lines/components & the rear is close to done:

Attached picture 6661071-7-Complete-2.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/01/11 01:37 PM

Car, at this stage (sans tank): (fuel system next....)

Starting to look mean ... (or at least I think so!!!)



Attached picture 6661078-7-Complete-5.jpg
Posted By: 70shaker6pk

Re: My 68 Hemi Charger Project -a little different - 06/02/11 02:00 PM

Also wanted to say great pic's and information, helps me when i get into my project. Really would like to hear it run with your exhaust system, bet it sounds great, And yes it's looking MEAN!!
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 08:54 AM

So, i'll get into the next phase (which is still presently in progress), being the fuel system.

Here's the requirements:
1. long range capacity
2. duel fuel (pump gas & E85)
3. deliver across the full range, including 1,500 hp
4. must retain high degree of injector resolution (i.e. tunability) at lower speeds
5. continuous duty low and/or easy maintenance
6. be externally tidy, concealed, appear "lightly" OEM.

Aeromotive helped me with the fuel system design. 16 injectors, 1 x 8 Primaries + 1 x 8 Secondaries.
I am running the Stage V single plane dual quad EFI manifold. We are modifying this for a single plenum and front mount throttle bodies.
We're looking at making dual-progressive intake throttle body assembly as one large TB will likely crack the throttle too far for street use.

I'll start at the tank end. I am using a new tank, modified to have EFI pumps installed. To deliver 1,275 lbs of fuel at full power I need two Aeromotive A1000 pumps. They are internally mounted.

Anyway here's the diagram from Aeromotive, note that it has changed with the use of another set of injectors.

Attached picture 6681987-0-C-A1KEFIDualIn-Tank.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 08:55 AM

the tank in place before work starts:

Attached picture 6681988-1-FuelTank-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 08:58 AM

not much space. I will be running 2 external filters outside the tank, up in the space we created in raising the axle hump. Will also be fitting charcoal canister in there (LH Side) for venting tank(s)..

Attached picture 6681989-1-FuelTank-2.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 08:59 AM

original filler tube, we are doing away with this.:

Attached picture 6681990-1-FuelTank-3.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:04 AM

This is the plan for the tank:

1. a sump in the centre of the tank, with one-way-check valves so fuel can only go in, ensuring that the sump is as full as it can be at any time;

2. the pump pickups (2) collect fuel from this sump;

3. there is an inspection plate over the sump (centre of tank), which can be accessed through a access panel made in the trunk floor;

4. there is a pump-mounting-plate, at the front of the tank from which the two pumps will be suspended, but able to be removed, through the same trunk floor access panel for servicing of the pumps or pickup filters (2);

4. Delivery (-10 x 2) and return (-10 x 1) exit through the front of the tank & clear all axle/moving components, incuding adequate distance from exhaust.

Attached picture 6681992-1-FuelTank-5.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:06 AM

as you may notice we used the structure of the internal sump to brace the tank to some degree. another pic:

Attached picture 6681994-1-FuelTank-6.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:08 AM

dry solder used to seal the sump and baffles. welding will cause rust.
all internal tank parts being anodized.
...E85...

Attached picture 6681995-1-FuelTank-7.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:09 AM

another pic/sump in place :

Attached picture 6681996-1-FuelTank-8.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:11 AM

note that the threaded nut plate in the last pic actually goes on the inside of the tank, and sandwiches the tank shell between it (using 2 gaskets) and the billet inspection plate.another pic:

Attached picture 6681997-1-FuelTank-9.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:13 AM

billet inspection cover/plate, pump mounting plate is the same. will have countersunk allen screws to hold/sandwich gaskets.:

Attached picture 6681998-1-FuelTank-10.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:14 AM

..how we anticipate mounting the pumps:

Attached picture 6681999-2-PumpMount-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 12:03 PM

final filter/pump assembly (ex wiring):

Attached picture 6682035-2-PumpMount-9.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 12:05 PM

another pic of pump assembly
primary pump is speed controlled, secondary pump will come on stream as referenced by boost & rpm (via ECM):

Attached picture 6682036-2-PumpMount-6.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 12:07 PM

in-tank pickups (2) & return (1):

Attached picture 6682037-3-InTank-2.jpg
Posted By: johnscudashop

Re: My 68 Hemi Charger Project -a little different - 06/14/11 04:52 PM

Darren, That is awesome!!! This post keeps getting better . Keep up the great work!
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:35 PM

thanks John, been too busy on other things to post pictures,. here's some more:
pump setup in tank 1:

Attached picture 6682703-4-Assembled-4.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/14/11 09:52 PM

To deal with the fuel range issue I am making two additional tanks that will fit inside each rear quarter, each will then feed into the main tank (which the pictures are of so far).

The std '68 filler cap will, inside the quarter be matched to the aluminium tank and replicated on the RH side (yes 2 x tanks). This should provide a half-decent range for the car. the distances are large here in Australia total system capacity will be about 50+ US gal.

Inside each aluminium tank housing will be a bladder (made by ATR in NJ), to cover safety issues & ensure the tanks aren't ruptured on side impact. Tank housing will run close to inside quarters approx 1" matching inside quarter contours. hopefully cutting templates this week will post pics. System will also detect sudden pressure loss, as in ruptured line(s), as a system kill condition/switch of controllers.

another of in tank setup 2:

Attached picture 6682727-4-Assembled-5.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/15/11 12:08 AM

and where fuel lines exit tank (2), then Y'd into the filter #12335 before heading to the engine end of the car, and return line comes back.:

Attached picture 6682936-4-Assembled-0.jpg
Posted By: Barnabas_Kriss

Re: My 68 Hemi Charger Project -a little different - 06/16/11 06:25 AM

VERY Impressive! Can't wait to see more.
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 06/16/11 09:27 PM

thank you! appreciate the positive comments on here, helps keeps the faith!!
Posted By: rayztoy

Re: My 68 Hemi Charger Project -a little different - 07/17/11 10:39 PM

Darren,
INCREDIBLE!! Thanks for sharing the build and the pics...

Ray
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 07/24/11 11:23 AM

thanks Ray
Appreciate comments keeps me motivated!

I haven't posted pic's in a while been too busy. planning to get back into it soon.
Fuel tanks that fit inside the rear quarters, that contour the inside (another 2 x 16 gals) are being fabricated with internal bladders now.

Darren
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 07/25/11 01:26 AM

here is the template I made for the additional RH inside quarter tank. We're drawing it up in CAD, will make the aluminium shell to test fitment, put mounting tabs etc in place, including making fittings to connect to main tank, & std filler cap's on both 1/4's.
We will then send the spec to ATL to make the internal bladders that will fit inside.

Attached picture 6745278-5-newTanks-1.jpg
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 07/25/11 01:33 AM

the LH side will be a mirror image. another angle:

Attached picture 6745294-5-newTanks-2.jpg
Posted By: MuuMuu101

Re: My 68 Hemi Charger Project -a little different - 08/30/11 07:04 PM

Any updates?
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 09/06/11 12:04 PM

sorry, yes it's been a while I've just been flat out.
Over the next couple of weeks I will be installing fuel system & plumbing etc. then pre-xmas getting the engine in, supercharger & pulleys/intercooler mounted etc.

thanks for the interest & support., big job!
Posted By: Hemidavey

Re: My 68 Hemi Charger Project -a little different - 10/03/11 03:20 AM

Awesome project! I've removed several of those "cast" Dana 60 covers from customers cars, they hit the gas tank! I'm curious about running 2 mufflers in series on each pipe, power loss??? Are you going for really quiet exhaust? Thanks for sharing your experiences as you progress.
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 10/06/11 11:27 AM

Thanks for your comments David, just getting back to working on my car again now . The two mufflers per side will hopefully quiet it a little, although I still expect it to be loud. I have plenty of wiggle room to work with with peak power around 1,500hp, it will be a regularly driven street car.

Hopefully, loads of more pictures as I get cracking on the next stages: full plumbing of fuel system, ISIS multiplexing , engine & custom pro charger & dual intercooler install. Loads to do.

Posted By: NV69B7RR

Re: My 68 Hemi Charger Project -a little different - 10/06/11 03:48 PM

Keep up the great work, can't wait to see more!!
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 03/18/12 07:13 AM

Just a note to thank everyone for their support on this project.

I know I haven't been on here for a long time.. and for even longer the project has been stalled as I just haven't the spare time or resources to move it along.
In fact, now it's just plain frustrating -- so I am going to sell the car to anyone who is interested in picking up the project to complete in their own way.

Please PM me if you're interested or with questions.

Thanks again everyone. I intend to pick up one for a weekend-driver in the meantime, then maybe in a few years do something again (when I know I can finish it).

Cheers, Darren

Attached picture 7123848-7-Complete-5.jpg
Posted By: MuuMuu101

Re: My 68 Hemi Charger Project -a little different - 03/18/12 08:28 AM

Quote:

Just a note to thank everyone for their support on this project.

I know I haven't been on here for a long time.. and for even longer the project has been stalled as I just haven't the spare time or resources to move it along.
In fact, now it's just plain frustrating -- so I am going to sell the car to anyone who is interested in picking up the project to complete in their own way.

Please PM me if you're interested or with questions.

Thanks again everyone. I intend to pick up one for a weekend-driver in the meantime, then maybe in a few years do something again (when I know I can finish it).

Cheers, Darren



WHAT!!!??? FOR SALE!!!! This was one of my favorite project builds.

I hope you find the car you want and that you can enjoy
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 03/19/12 12:52 AM

thank you I will, and thanks again to everyone on the site.

Anyone interested in buying the project as it stands please feel free to PM me.
I will not sit on it for long to hold out for every last $ as I intend to move on quickly.




Posted By: MuuMuu101

Re: My 68 Hemi Charger Project -a little different - 03/19/12 06:07 AM

If I had the money, I would buy your car within a heartbeat, but sadly I have no where near the funds to buy a project like yours.
Posted By: Anonymous

Re: My 68 Hemi Charger Project -a little different - 03/22/12 05:08 AM

I think you will regret selling this work of art, you are almost there. I vote for you keeping the car and finishing it and not lose a lot of money on a fire sale.
Posted By: Hemi ragtop

Re: My 68 Hemi Charger Project -a little different - 03/23/12 01:12 AM

Quote:

thank you I will, and thanks again to everyone on the site.

Anyone interested in buying the project as it stands please feel free to PM me.
I will not sit on it for long to hold out for every last $ as I intend to move on quickly. Move on to what? Man this has been your dream, you have put your heart into it. This is your expression of YOU and your unique vision for a Charger. If you have to take a break, so be it, but like others have stated, you will never get a monetary reward for your efforts, much less your investment. STAY IN THE GAME SON! Finish what you started, that is your destiny!








Attached picture 7130973-DSCN0128.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 03/25/12 12:24 AM

"stay in the game son"

Well.

Change of plan. I will finish the car. It seems a lot of people have reached the point I got to before on their projects. The amount of people saying NO! don't sell it and encouragement has been overwhelming.

So, officially, it's back on (withdrawn from sale).

I hope everyone forgives me! Surely everyone is entitled to at least one brain f-rt in the lifetime (in my case maybe quite a few more).

I will make a priority getting some paint on it. I think that will spur another round of motivation.

thanks again everyone
Posted By: MuuMuu101

Re: My 68 Hemi Charger Project -a little different - 03/25/12 05:37 AM

Yes! Get that car done!
Posted By: NV69B7RR

Re: My 68 Hemi Charger Project -a little different - 03/25/12 03:43 PM

Thats awesome you're sticking with it. Yes, some paint will really go a long way for motivation. If u need a break from it then do so, and come back to it. That car is a huge part of you.

I find watching Eric Bana's "Love The Beast" every now and then helps with motivation.
Posted By: 70B5Cuda

Re: My 68 Hemi Charger Project -a little different - 03/30/12 04:17 AM

I am glad you are keeping it. You have everything to lose and nothing to gain by selling now. Good choice.
Posted By: 72Swinger

Re: My 68 Hemi Charger Project -a little different - 04/24/12 11:28 PM

Absolutely wicked build Darren! Keep on keepin on!
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 12/12/12 08:32 PM

It's back on! Full speed to get finished in 2013.



Posted By: Anonymous

Re: My 68 Hemi Charger Project -a little different - 12/13/12 03:22 AM

Excellent!
Any update pics?
Posted By: NV69B7RR

Re: My 68 Hemi Charger Project -a little different - 12/13/12 04:56 AM

Right on! Glad to hear it
Posted By: MuuMuu101

Re: My 68 Hemi Charger Project -a little different - 12/13/12 06:47 AM

Quote:

It's back on! Full speed to get finished in 2013.







YES!!!
Posted By: studio57

Re: My 68 Hemi Charger Project -a little different - 12/29/12 08:23 PM

Amazing job , lot of similar updates i have on my car.. i think yours will be even better than mine is when it is done !!
keep up the good work !
Masi
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 12/29/12 10:25 PM

thanks everyone ... into the engine stage now ..
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/18/13 10:47 PM

More updates coming soon ...


Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/19/13 11:10 PM

The engine build commences .....Cylinder Heads #1:

Attached picture 7711707-1-Heads-01.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/19/13 11:13 PM

Cylinder Heads #2

Attached picture 7711714-1-Heads-02.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/19/13 11:16 PM

Cylinder Heads #3

Attached picture 7711721-1-Heads-03.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/19/13 11:18 PM

Cylinder Heads #4

Attached picture 7711729-1-Heads-04.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/19/13 11:19 PM

Cylinder Heads #5:

Attached picture 7711731-1-Heads-05.JPG
Posted By: Keith Black®

Re: My 68 Hemi Charger Project -a little different - 05/19/13 11:22 PM

Cylinder Heads 6 - Flow & Setup Data:

Attached picture 7711736-1-Heads-FlowNumbers.jpg
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