Sublime Lime 70 Challenger R/T SE

[Dodgey]

Another weekend gone and a dew more small bits of progress. Cleaned up the inside of the sill area, made up a patch for the rusted section of the inner sill area and replaced the top half of the forward sill end cap. Combination of rust and casualty of removing the old sill. One more patch to do on the inside sill lip, then I can paint it all up and weld on the new sill. I'm about to head away for work for a couple of weeks, so might have to wait a bit ...

 

[Katfish]

Keep at it, looking good!

 

[Dodgey]

Made up and welded in a replacement bottom section for the inner quarter panel section. Ultimately not sure what you call it, but that'll do. Almost at the point where I can paint all the exposed metal surfaces and spot weld the sill back in. Still a bit of surface clean up to do ahead of painting though. Although that should go pretty quickly.

 

[Dodgey]

Had a pretty productive weekend. Managed to make a decent amount of progress on the passenger side. Granted I painted the sill sections last weekend.
Inner sill sections epoxy primed, contact points weld through primer.

Spot welded the sill on and had to persuade the front door hinge panel lower sections back in place. Still need to clean it up and give the outside a quick hit of primer to seal it all up again.

Spent quite a bit of time lining up the rear inner quarter section. Due to the amount of rust repairs I'd had to make, the whole section was floating. Sitting there loosely, the passenger side of the rear window corner had drooped, so I had my laser level out lining things up so that left to right they are the same height from a level line across the rear floor. Spot welded the inner quarter panel to the top of the sill section, then re-installed the brace. I had to build up a fairly large section of the rear brace as that had rusted badly and was paper thin against the inner quarter panel.
Quick coat of weld through primer on the contact points and epoxy primer on the remainder of both the rear door jamb and the inner quarter panel. I'll check the door opening and weld in the jamb next weekend. At that point I will clean up the outside of the sill and epoxy prime all the remaining sections of the sill and jamb etc to seal it all up while I tackle the rust on the sail panel section.

 

[Katfish]

Wow, lots of progress!
How many hrs for just that 1 section?

 

[don selleck]

beautiful work!

 

[Dodgey]

Wow, lots of progress!
How many hrs for just that 1 section?

Thanks!

I don’t really count them, but there’s probably something like 10-16 hours a weekend I put into it. I had a couple of weekends I was away for work, so at a guess about 50 hours since the last post.

Granted I get side tracked on other things as well, so maybe not quite that many. Good thing I’m not paying for my labour

 

[Dodgey]

Got the passenger side door jamb pillar installed, although neglected to take a photo of it ...

Once I got that completed, it was onto the sail panel brace structure. Started with the top one. As you can see from the pic, only the upper facing surface was still intact.

I shaped the side and bottom as two separate pieces. Bead rolled the side section to get the drip rail relief in it. The bottom section bent the flange, then using the shrinker, stretcher to get the correct curve on it then TIG welded it all together. Unfortunately AMD only make the front section of the 4 pieces (the primed forward piece is an AMD piece).

I'll Start on the next one down next weekend, same approach. Once I've got the braces made up and removed, I'll tackle the inner sheet metal, as you can see it's got a little rust in it as well.
Sometimes I wonder why ... but then I stop and look what I've done so far and I think it's worth it.

 

[Katfish]

Good progress, nice!