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Re: Jake's Challenger/Rust [Re: jake71] #519265
11/10/09 09:20 AM
11/10/09 09:20 AM
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Posts: 290
Loveland Colorado
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jake71 Offline OP
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Here's the pan all laid out for plug weld holes.

5596826-challenger228.jpg (207 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519266
11/10/09 09:22 AM
11/10/09 09:22 AM
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Loveland Colorado
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jake71 Offline OP
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Here we're all drilled and deburred. I coated the deburred areas on the back with weld through primer before laying the pan in place.

5596831-challenger232.jpg (203 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519267
11/10/09 09:27 AM
11/10/09 09:27 AM
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Loveland Colorado
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jake71 Offline OP
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And the frame rails marked for grinding through the POR15 for weld through primer. Later I determined I could save myself this extra work and time by just skipping this step and using my Dremel tool with a little burr bit in it. Just lay the part in place and burr the POR15 just inside the plug weld hole to expose the metal for welding. It works awesome.

5596840-challenger234.jpg (184 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519268
11/10/09 09:29 AM
11/10/09 09:29 AM
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Loveland Colorado
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All welded in. The Goodmark pan was a very good fit that required only massaging the edges here and there. No cutting at all.

5596845-challenger245.jpg (232 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519269
11/10/09 09:31 AM
11/10/09 09:31 AM
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Loveland Colorado
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jake71 Offline OP
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Here are some close up shots to show how well it fit even with the hand made patches around the bottom of the wheel houses.

5596849-challenger253.jpg (194 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519270
11/10/09 09:32 AM
11/10/09 09:32 AM
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Loveland Colorado
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jake71 Offline OP
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Loveland Colorado
I've got a few of these. Let me know if it's too much and I'll back off a bit.

5596855-challenger255.jpg (220 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519271
11/10/09 09:33 AM
11/10/09 09:33 AM
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Loveland Colorado
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jake71 Offline OP
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Loveland Colorado
For your viewing pleasure.

5596856-challenger257.jpg (212 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519272
11/10/09 09:34 AM
11/10/09 09:34 AM
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Loveland Colorado
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jake71 Offline OP
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And more.

5596860-challenger258.jpg (160 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519273
11/10/09 09:36 AM
11/10/09 09:36 AM
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Loveland Colorado
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jake71 Offline OP
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Like I said, I have a few of these but I always wish there just a few more detail shots for reference when I'm looking at these posts.

5596864-challenger259.jpg (183 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519274
11/10/09 09:37 AM
11/10/09 09:37 AM
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Loveland Colorado
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jake71 Offline OP
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Almost done.

5596867-challenger261.jpg (168 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519275
11/10/09 09:37 AM
11/10/09 09:37 AM
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Loveland Colorado
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jake71 Offline OP
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Last one.

5596869-challenger295.jpg (212 downloads)
Re: Jake's Challenger/Rust [Re: jake71] #519276
11/10/09 09:38 AM
11/10/09 09:38 AM
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Loveland Colorado
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jake71 Offline OP
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Well, thank you all for your time and well wishes. I'll be back later with more.

Re: Jake's Challenger/Rust [Re: jake71] #519277
11/10/09 12:59 PM
11/10/09 12:59 PM
Joined: Jan 2003
Posts: 1,756
London, England
Gavin Offline
top fuel
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Keep 'em coming, can't have too many pictures!!

Fabulous work, well done

Re: Jake's Challenger/Rust [Re: Gavin] #519278
11/10/09 02:29 PM
11/10/09 02:29 PM
Joined: May 2009
Posts: 60
Lynchburg, VA
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ridenlow12 Offline
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Lynchburg, VA
Keep'em comming. This is very good diy information to have and not have to pay for

Re: Jake's Challenger/Rust [Re: ridenlow12] #519279
11/10/09 02:34 PM
11/10/09 02:34 PM
Joined: Aug 2004
Posts: 8,526
Tenn.
jrwoodjoe Offline
master
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Tenn.
Great pics showing the progress. WOW, you are a brave man. I don't think I could have tackled that but it looks like you are doing a FANTASTIC job with it. Looking forward to more pics.

Joe



65 Barracuda
70 Challenger
Re: Jake's Challenger/Rust [Re: Gavin] #519280
11/10/09 03:10 PM
11/10/09 03:10 PM
Joined: Nov 2009
Posts: 61
Brighton, MI, USA
kb73rr Offline
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Brighton, MI, USA
You're doing an amazing job! You are definitely saving one that many people would consider too far gone. So much the better when you're done.

I have one question. Hopefully it won't open up a can of worms. Are you using the POR15 self-etching primer (spray) or the brush on stuff?

I had a lot of sheet metal work done on my car including a bunch of rust repair fabrications just like you're doing. The guy who did the work was well regarded pro with about 20 years experience. He does some very high dollar cars including a number of Autorama show winners. Every last millimeter of bare metal got cleaned with skotchbrite, rinsed and wiped, then coated with SEM self-etching primer. The skotchbrite and rinse had to be done within minutes of spraying the primer. He said it was the only way to guarantee it wouldn't rust. Five years later and none of the work he did shows any indications of rust.

I did my front and back bumper mounts/supports myself. I used POR15. I did the front ones before I learned about the SEM, and didn't use it. I did the back the same way he did with the scotchbrite, rinse and SEM before the POR. That was also 5 years ago, and the car has never been caught in anything worse than a light drizzle since. The back still looks 100% perfect, the front is showing a little rust. That just my personal experience. Your results may vary ha ha ha.

Anyhow - here is a big pat on the back for your work and thanks for your time posting it!

Last edited by kb73rr; 11/10/09 06:56 PM.
Re: Jake's Challenger/Rust [Re: jake71] #519281
11/10/09 05:47 PM
11/10/09 05:47 PM
Joined: Mar 2009
Posts: 583
Raleigh, NC
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rockerbob Offline
mopar
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Raleigh, NC
Quote:

I've got a few of these. Let me know if it's too much and I'll back off a bit.




You are doing a great job. Please keep the pic's comming. Thanks so much!


2005 Dakota 4X4 3.7 2004 Rumble Bee 5.7 1978 Diplomat 318 1969 Satellite 318 "bracket racer" 1966 Barracuda (in progress ) 1964 Dodge 330 (future race project) 1962 Belvedere (HUM????)
Re: Jake's Challenger/Rust [Re: kb73rr] #519282
11/10/09 07:07 PM
11/10/09 07:07 PM
Joined: Nov 2009
Posts: 290
Loveland Colorado
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jake71 Offline OP
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Quote:

You're doing an amazing job! You are definitely saving one that many people would consider too far gone. So much the better when you're done.

I have one question. Hopefully it won't open up a can of worms. Are you using the POR15 self-etching primer (spray) or the brush on stuff?

I had a lot of sheet metal work done on my car including a bunch of rust repair fabrications just like you're doing. The guy who did the work was well regarded pro with about 20 years experience. He does some very high dollar cars including a number of Autorama show winners. Every last millimeter of bare metal got cleaned with skotchbrite, rinsed and wiped, then coated with SEM self-etching primer. The skotchbrite and rinse had to be done within minutes of spraying the primer. He said it was the only way to guarantee it wouldn't rust. Five years later and none of the work he did shows any indications of rust.

I did my front and back bumper mounts/supports myself. I used POR15. I did the front ones before I learned about the SEM, and didn't use it. I did the back the same way he did with the scotchbrite, rinse and SEM before the POR. That was also 5 years ago, and the car has never been caught in anything worse than a light drizzle since. The back still looks 100% perfect, the front is showing a little rust. That just my personal experience. Your results may vary ha ha ha.

Anyhow - here is a big pat on the back for your work and thanks for your time posting it!



Thank you for the compliment. It was pretty far gone but they're getting harder to find, especially these options, and I figure it will be well worth the experience. At least I didn't just pay someone to do it all for me right? I know some stuff is out of people's scope but I always admire someone doing what they can on their own car.
As for the POR15, I did it like the directions said. They have their metal prep that you spray on and rinse off. That stuff has a pretty harsh reaction with bare metal. It smells like rust converter and it really seems to etch the metal pretty well. I'm going to scuff all that I can reach before any sprayables go on and then the entire thing is getting a couple coats of direct to metal epoxy primer. I hope that this is the right thing to do. The guy at my local paint supply house seems to think I will never have any problems. Hope he's right!

Re: Jake's Challenger/Rust [Re: Gavin] #519283
11/10/09 07:10 PM
11/10/09 07:10 PM
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Posts: 290
Loveland Colorado
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jake71 Offline OP
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Quote:

Keep 'em coming, can't have too many pictures!!

Fabulous work, well done



Thank you very much. It means alot coming from any admirer but after seeing your work I'm proud of the compliment. Great metal work!

Re: Jake's Challenger/Rust [Re: rockerbob] #519284
11/10/09 07:12 PM
11/10/09 07:12 PM
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Posts: 290
Loveland Colorado
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jake71 Offline OP
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Quote:

Quote:

I've got a few of these. Let me know if it's too much and I'll back off a bit.




You are doing a great job. Please keep the pic's comming. Thanks so much!



Thank you. I'm happy you are enjoying it, kinda feels like my own little TV show!

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