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Episode Transcript
(NARRATOR) TODAY ON DETROIT MUSCLE PROJECT "HARD CHARGER", OUR '69 DODGE, IS BACK IN THE SHOP AND SHE'S IN NEED OF SOME SERIOUS METAL WORK. WE'LL DO SOME AUTOMOTIVE ARCHEOLOGY TO SEE JUST HOW UNKIND FATHER TIME HAS BEEN TO OUR OLD MOPAR.
(TOMMY) HEY GUYS, GLAD YOU COULD JOIN US. NOW TODAY WE'RE GONNA BE JUMPING BACK ON OUR '69 DODGE CHARGER PROJECT, AND WE'RE GONNA BE WORKING ON THESE LOWER QUARTERS WHERE IT'S GOT SOME RUST IN THEM. NOW WE'RE EXPECTING TO OPEN UP A CAN A WORMS BUT THAT'S OKAY. NOW WITH THIS PROJECT WE'RE TRYING TO KEEP IT RUNNING AND DRIVING AS MUCH AS POSSIBLE BUT SOMETIMES WE'RE NOT GONNA BE ABLE TO. (MARC) THAT'S RIGHT, AND WHILE TOMMY'S DOING THAT I'M GONNA BE BACK ON OUR BIG OLE MERCURY HERE. I'M JUST GONNA GIVE IT A ONCE OVER SINCE IT'S BEEN OUT ON THE ROAD, AND THERE'S A COUPLE OF LOSE ENDS THAT WE DIDN'T GET DONE BEFORE ITS MAIDEN VOYAGE. (TOMMY) NOW WHILE WE WERE DOWN THERE IN LA, LOWER ALABAMA, WE SAW SOME TELLTALE SIGNS THAT THIS THING LOOKS LIKE IT HAD SOME RUST IN IT, AND THEN THERE'S ANOTHER BACK HERE ON THE BACK TOWARD THE LIP. THE NEXT THING I'M GONNA USE A VERY COMPLEX TOOL. A PIECE OF US CURRENCY, TAP ON THE PANEL. UP HERE SOUNDS LIKE METAL. AS YOU GET OVER HERE SOUNDS A LITTLE BIT LIKE PLASTIC. EITHER WAY A REPAIR NEEDS TO BE MADE FOR THE TYPE OF CAR THAT WE'RE PUTTING TOGETHER. SO WE'RE GONNA DIG IT OUT AND SEE WHAT WE'RE WORKING WITH. I'M GONNA TAKE THIS GRINDER AND RUN RIGHT ACROSS THE TOP OF THOSE LITTLE BUMPERS, AND LET'S SEE WHAT'S IN THERE. [ grinder spinning ]
(TOMMY) YOU CAN SEE THERE'S SOME RUST AND CORROSION UNDER THE FILLER HERE. WELL LET'S GO AHEAD AND STRIP THE REST OF THIS PANEL AND SEE WHAT WE'RE WORKING WITH. WE'RE GONNA TAKE THIS A LITTLE AT A TIME BECAUSE WE DON'T KNOW YET JUST HOW EXTENSIVE THE SINS ARE ON THIS PANEL. IT'S LOOKING LIKE THIS PARTICULAR PIECE OF REAL ESTATE IS GONNA NEED A LOT OF HELP, WITH AS THICK AS THIS MUD IS. YOU'RE REALLY NOT SUPPOSED TO GO OVER AN EIGHTH INCH MOST OF THE TIME, AND WE'RE WAY PAST THAT. WELL THIS OLE CAR'S GOT QUITE A BIT OF FILLER IN IT DOWN HERE. SO WE'RE GONNA HAVE TO CHANGE OUR PLAN OF ATTACK AND STRAP ON ONE OF THESE MASKS. THE FURTHER I GO WITH MY GRINDER THE MORE FILLER I FIND ON THIS THING. LOOKS LIKE THE WHOLE PANEL HAS BEEN MUDDED UP.
WELL IT LOOKS LIKE ALL OF OUR PANEL UP HERE IS GOOD. IT JUST HAD KIND OF A POOR PATCH BACK HERE IN THE BACK, BUT BEFORE I CAN SAY, "WE CAN PATCH FROM HERE DOWN", I ACTUALLY NEED TO STRIP MORE OF THIS QUARTER TO MAKE SURE THAT THE REPAIR DOESN'T NEED TO GO FURTHER UP HILL. [ grinder spinning ] (TOMMY) WELL WE'RE GONNA HAVE TO KEEP CHASING THIS FILLER BECAUSE WE WANT TO MAKE SURE THAT WE DO THE CORRECT REPAIR. NOW SOMEBODY PUT FILLER ON WAY TOO THICK AND WE'VE GOT TO MAKE SURE THERE'S NO HIDDEN SINS UNDER ALL OF IT.
AFTER QUITE A BIT OF ARCHEOLOGY HERE THIS OLE CAR NEEDS A SKIN PUT ON IT. I'M DONE! THE AMOUNT OF FILLER HANGING OFF THE SIDE OF THIS CAR YOU COULD SAY WOULD BE A LITTLE BIT EXCESSIVE, AND A PRETTY GOOD INDICATION OF THAT IS THIS MOUNTAIN OF DUST HERE IN THE FLOOR, AND ALL OF THAT COME OFF OF JUST ONE SIDE. NOW AFTER GETTING IT ALL STRIPPED DOWN WE NOTICED THAT THIS CAR'S HAD A COUPLE OF PRIMITIVE REPAIRS DONE TO IT, AND DOWN HERE ON THE BOTTOM WHEREVER THEY WELDED IT IN THEY WARPED THE HECK OUT OF THE PANEL AND THEN TOOK A HAMMER AND BEAT IT ALL IN TRYING TO MAKE IT BETTER. WELL THIS IS A PERFECT EXAMPLE OF WHAT I'VE SAID IN THE PAST. IT MAY BE BOOGERED UP AND LOOK BROKEN, BUT IT AIN'T PLUM BROKER UNTIL YOU CAN'T FIX NO MORE. (MARC) AND THIS IS HOW WE'RE GONNA FIX IT. WE WENT TO STEPHENS PERFORMANCE BECAUSE THEY'RE RIGHT UP THE ROAD AND THEY'VE GOT THE GOOD STUFF. THIS QUARTER SKIN CAME FROM AUTO METAL DIRECT. IT'S OE GAUGE STEEL, AND LIKE THEIR OTHER PANELS, COMES WITH THEIR RELIABLE ECOAT. THE TOP OF THIS SKIN EXTENDS ALL THE WAY PAST THIS UPPER BODY LINE BY AT LEAST A HALF AN INCH. SO IF YOU DON'T NEED A FULL QUARTER PANEL YOU CAN GET ONE OF THESE AND IT'LL SAVE YOU OVER $200 BUCKS. IT'S THE SAME STORY ON THE FRONT AND REAR OF THE PANELS AS WELL AS AROUND THE WHEEL WELLS WITH THAT EXTRA OVERHANG FOR EASY INSTALLATION.
SINCE WE'RE GONNA BE SLINGING A LOT OF WELDING SPARKS WE'VE GOT TO GO AHEAD AND PULL THE GAS TANK. NO NEED TO TAKE THE RISK OF LEAVING IT IN. THERE'S ALSO A FEW THINGS THAT ARE IN THE WAY AND NEED TO COME OFF, LIKE THE BUMPER, MARKER LIGHT, AND THIS QUARTER EXTENSION.
(TOMMY) WE'RE PRETTY MUCH READY TO START THROWING SOME SPARKS AND THE FIRST INCISION WE'RE GONNA MAKE IS RIGHT HERE ON THE TOP SIDE OF THE QUARTER PANEL ABOUT THREESIXTEENTHS UP, AND THEN WE'RE GONNA COME BACK WITH THAT BIG OLE GRINDER AND WHACK OFF THE MAJORITY OF THIS QUARTER TO GET IT OUT OF THE WAY, AND THEN FOLLOW UP WITH SOME DRILL BITS AND THAT KIND OF THING TO GET THE REST OF IT OFF. THAT WAY WE CAN COVER QUITE A BIT OF GROUND PRETTY QUICKLY. FIRST THINGS FIRST, WE'VE GOT TO MAKE SOME MARKS.
NOW THIS MARK DOWN THROUGH HERE DOESN'T HAVE TO BE VERY ACCURATE BUT WE'LL JUST GO AHEAD AND MARK IT. (MARC) SOME WELDING PAPER IS A GOOD IDEA TO PROTECT YOUR GLASS FROM ALL OF THOSE CUTTING AND WELDING SPARKS. NOW WE CAN BUST OUT THE CUTTING WHEEL AND START GETTING THIS QUARTER OFF.
[ saw cutting metal ] (TOMMY) WE'VE GOT A LITTLE SPOT RIGHT HERE WHERE THEY MANAGED TO WELD THE OUTER SKIN TO THE INNER ONE. SO I'VE GOT TO CUT THAT FREE. [ saw cutting metal ]
(TOMMY) AND WHEN YOU PULL THE PANEL OFF DON'T LET YOUR GRINDER CORD GET CAUGHT ON ITS WAY DOWN.
AH! (NARRATOR) NOW THAT THE BIG PIECES ARE OUT OF THE WAY IT'S TIME TO GET A LITTLE MORE DELICATE ON OUR QUARTER PANEL REPLACEMENT.
(TOMMY) HEY FOLKS, GLAD YOU MADE YOUR WAY BACK. NOW WE GOT MOST OF THAT QUARTER OUT OF THE WAY. NOW WE'VE GOT TO WORK ON GETTING THE REST OF IT MOVED AWAY AS WELL. NOW I'M GONNA USE THIS GRINDER HERE TO DO A LITTLE MASSAGING HERE ON THE BACK SO THAT WE CAN HIGHLIGHT THOSE SPOT WELDS. THEN WE'LL GET AFTER IT WITH A DRILL. TIME TO GET STARTED. [ grinder spinning ]
(TOMMY) WELL LOOKS LIKE WE'VE GOT A SPOT WELD HERE, PROBABLY ONE THERE, RIGHT THERE, RIGHT THERE, AND I'D SAY THERE, POSSIBLY THERE TOO. [ saw cutting metal ] (TOMMY) I'LL USE A BODY SAW TO GET RID OF THIS SIDE PIECE AT THE BACK OF THE QUARTER. IT'S GOING AWAY ANYHOW, AND WITH IT GONE THE REMAINING PIECE WILL BE EASIER TO REMOVE. [ saw cutting metal ]
(TOMMY) NOW WE CAN JUST BUST OUT THE SPOT WELD DRILLER AND GET BUSY ON THIS TAIL PIECE. YOU CAN DO THIS WITH A DRILL TOO BUT IT TAKES A LITTLE MORE PATIENCE. WHEN YOU GO TO SEPARATE THE PIECES YOU MIGHT FIND ONE OR TWO MORE WELDS. JUST TAKE CARE OF THEM IF YOU FIND THEM. WELL YOU GUYS GOT TO SEE THE TECHNIQUE THAT I'VE GOT TO APPLY ALL THE WAY DOWN, FORWARD, AROUND THE FENDER WELL, AND UP TO THE DOOR. SO IT'S TIME TO GET BUSY.
[ grinder spinning ]
(TOMMY) WE MADE SOME PRETTY GOOD PROGRESS PREPPING FOR THE NEW QUARTER SKIN. WHENEVER I MOVE DOWN HERE TO THE BOTTOM OF THE QUARTER PANEL I NOTICED SOMEONE HAS DONE SCREWED UP THE INNER STRUCTURE AS WELL. IT'S GOT QUITE A BIT OF RUST RIGHT IN THROUGH HERE. SO THAT MEANS THIS PIECE IS GONNA HAVE TO BE REPLACED AS WELL. [ air hammer vibrating ] (MARC) THIS OLD COATING HAS TO BE REMOVED TO GET TO THE METAL, AND THE AIR HAMMER WILL HELP GET THAT DONE.
THEN IT'S MORE QUALITY TIME WITH THE BODY SAW. IF YOU'RE GONNA BE DOING MUCH PANEL WORK ONE OF THESE SAWS LIKE THIS ONE FROM MATCO IS JUST ABOUT THE HANDIEST THING YOU COULD HAVE. (TOMMY) GOING THIS DEEP INTO THE REPAIR IS A NECESSARY EVIL BECAUSE YOU DON'T WANT TO BUILD A HOUSE ON A BAD FOUNDATION, AND IF WE JUST REPLACED METAL OVER THE TOP OF THIS STUFF THIS INNER METAL WILL CONTINUE TO DETERIORATE. WELL WITH THAT OLD PIECE OFF THAT EXPOSED SOME MORE BAD NEWS, BUT THAT'S ALL RIGHT. WE'RE GONNA HAVE TO JUST KEEP DIGGING ON THIS OLE CAR UNTIL WE'RE STANDING ON SOLID GROUND. [ grinder spinning ]
(TOMMY) WELL WE GROUND OFF ALL THAT FILLER AND ALL OF THAT STUFF WAS PRETTY MUCH A PERFECT EXAMPLE OF BURYING BAD BODY WORK OR BAD METAL WORK. THERE WAS REALLY NO REASON FOR THAT STUFF TO BE THAT THICK IF IT HAD DONE PROPERLY. SO WHAT WE'RE GONNA HAVE TO COME BACK AND DO IS CUT ACROSS HERE RIGHT AROUND THIS BAD PATCH, AND THEN KIND OF MOVE FORWARD FROM THERE. THERE'S NO REAL REASON WHY TO REPLACE THIS ENTIRE TAIL PANEL WHENEVER WE CAN MAKE A CORRECT PANEL REPAIR RIGHT HERE AND THEN ADD IN THAT NEW CORNER. [ saw cutting metal ]
[ drill spinning ] [ air hammer vibrating ] [ grinder spinning ]
(NARRATOR) AFTER THE BREAK, SEE HOW TO FABRICATE ONE OF THOSE TRICKY CORNER PIECES.
(TOMMY) HEY GUYS, WELCOME BACK. WE'RE MAKING SOME PRETTY GOOD PROGRESS ON OUR OLE MOPAR HERE. WE STARTED OFF BY CUTTING OFF A MAJORITY OF THAT QUARTER PANEL, AND THEN COME BACK AND GOT RID OF ALL THE TRIMMINGS. NOW AS WE WERE DOING THAT WE NOTICED THAT THIS TRUNK PAN EXTENSION WOUND UP HAVING SOME RUST IN IT AND SOMEBODY HAD BUGGERED IT UP DURING THE REPAIR, AND THEN WE WOUND UP FINDING BACK HERE ON THE CORNER SOMEBODY TRIED TO BURY A WHOLE BUNCH OF BAD DECISIONS. (MARC) HEY MAN, I THOUGHT YOU WERE SUPPOSED TO BE PUTTING PARTS ON THE CAR? (TOMMY) WELL I'VE BEEN TRYING TO BUT I KEEP FINDING BAD SPOTS HERE AND THERE, IF YOU KNOW WHAT I'M SAYING. (MARC) YEAH, WELL IT'S GETTING THERE I GUESS. (TOMMY) HOW'S THAT MERCURY COMING? (MARC) IT'S COMING, YOU KNOW, I'VE GOT A LOT GOING ON. THE WOBBLER SHAFT IS LOOSE, THE GIGGLING PIN'S MISALIGNED, SO I'VE JUST GOT A LOT GOING ON. (TOMMY) I THINK I'M PICKING UP WHAT HE'S PUTTING DOWN, AND IT'S COOL, GO AHEAD, I'LL DO THIS SHEET METAL WORK THAT I KNOW YOU DON'T LIKE. IT'S ALL GOOD. HE'S ONE OF THOSE. THE NEXT REPAIR WE'RE GONNA HAVE TO MAKE IS THIS LITTLE CORNER DOWN HERE CAUSE IF YOU NOTICE IT'S KINDA RUSTY AND THAT EDGE ISN'T EXISTENT ANY MORE. SO WE'LL JUST FAB THAT PIECE UP, NO BIG DEAL. WE ALSO NOTICED WHENEVER THEY MADE THAT REPAIR WAY BACK WHEN THAT THEY SLICED INTO THIS INNER ROCKER. SO WE'LL HAVE TO WELD IT UP. NO, WE'RE NOT GONNA CUT UP THIS NEW QUARTER YET BUT WE ARE GONNA USE IT FOR A TOOL TO HELP MAKE THIS PATCH FOR THIS PIECE. SO WHAT WE'RE GONNA DO IS LAY IT UP HERE AND IF YOU NOTICE, SINCE THAT PIECE IS RUSTY, WE'VE GOT TO MAKE SURE THAT WE HAVE AN ACCURATE PATCH. SO FIRST THINGS FIRST, A PIECE OF PAPER.
NOW YOU WANT TO MAKE SURE NOT TO SLIDE THE PAPER AROUND SO THAT YOUR LINE IS AS ACCURATE AS POSSIBLE. THAT SHOULD GET US WHAT WE NEED.
I'M GONNA CUT THIS JUST A LITTLE BIT BIGGER THAN OUR LINE. THAT WAY I CAN FILE IT DOWN TO SIZE WHEN WE GO TO PUT IT IN PLACE.
ABOUT THAT BIG. SO LET'S MAKE IT JUST A LITTLE BIGGER. GOOD PIECE OVER THERE.
[ saw cutting metal ] (TOMMY) WE WON'T BE ABLE TO MAKE THE ENTIRE THING OUT OF JUST ONE PIECE SINCE THE CURVED PART OF THE LIP WILL HAVE TO BE DONE SEPARATELY, BUT IN THE MEAN TIME WE'LL MAKE AS MUCH AS WE CAN OUT OF THIS ONE PIECE.
WE'LL STICK IT IN A VICE AND USE A BODY HAMMER TO BEND THIS PART OF THE LIP DOWN WHERE IT NEEDS TO BE.
NOW TO MAKE THIS PIECE MATCH THIS OLD PIECE IT NEEDS TO HAVE, WE'VE GOT TO FLIP AROUND RIGHT, YEAH, A LITTLE BIT OF A CURVE INTO IT, AND TO DO THAT WE'RE GONNA KEEP USING THIS VICE. [ hammer tapping ] (TOMMY) THE NEXT THING WE NEED TO DO IS BEND UP A PIECE OF METAL SO WE CAN FINISH OFF THAT LIP THAT WRAPS AROUND. NOW I'VE GOT A COUPLE OF OLD DROPS HERE THAT I THINK WE CAN MAKE IT OUT OF. LET'S SEE IF IT'LL WORK. [ hammer tapping ] (TOMMY) WHAT WE'LL DO IS SHAPE IT A LITTLE, THEN TRIM IT A LITTLE, AND GO BACK AND FORTH DOING THAT UNTIL WE GET WHERE WE WANT IT TO BE.
[ saw cutting metal ]
(TOMMY) THAT'S CLOSE ENOUGH WE CAN TAG THAT DUDE TOGETHER RIGHT THERE. OUR ESAB WELDERS ARE GONNA SEE QUITE A BIT OF ACTION TODAY, AND THIS IS JUST THE FIRST BIT OF IT. [ welder crackling ]
(TOMMY) WITH IT ALL WELDED UP WE CAN TRIM OFF THE EXCESS METAL AND GET IT READY TO FIT THE CAR. WE'LL ALSO GRIND IT DOWN TO MAKE IT LOOK NICE.
YEAH I BELIEVE THAT'S GONNA WORK JUST FINE. I DO HAVE TO TRIM OFF THE TOP AND THE SIDE JUST A BIT CAUSE IF YOU REMEMBER I MADE IT A LITTLE BIT LONG TO GIVE ME SOME WIGGLE ROOM, AND I'VE GOT A LITTLE BIT TOO MUCH RIGHT NOW. SO I'LL TRIM THEM BACK AND THEN ROLL THIS EDGE JUST A BIT TO MATCH THAT CONTOUR. WE CAN BURN THIS THING IN. [ welder crackling ] [ grinder spinning ]
(NARRATOR) STILL AHEAD WE'RE READY TO START BURNING THIS BABY BACK TOGETHER.
(TOMMY) HEY WE'RE BACK. NOW IF YOU GUYS HAVE BEEN WATCHING WE'VE BEEN WHITTLING AWAY AT OUR OLE MOPAR HERE CUTTING OUT SOME OF THAT BAD METAL AND WE'RE FINALLY TO A POINT THAT WE GET TO WELD IN SOME NEW METAL, LIKE THIS TRUNK FLOOR EXTENSION THAT WE GOT FROM AUTO METAL DIRECTION. I WENT AHEAD AND PUNCHED A FEW HOLES IN THIS TRUNK FLOOR SO THAT WE CAN MAKE SOME ROSETTE WELDS TO ATTACH THAT NEW FLOOR EXTENSION, AND THE REASON I DONE ON THIS SIDE IS BECAUSE YOU CAN REACH IT WITH THE WELDER. IF YOU PUT IT ON THE OTHER SIDE IT'S NOT GONNA BE VERY EASY AT ALL. (MARC) BEFORE WE GET TO EXCITED WE'LL CLAMP THIS PIECE FOR NOW SO WE CAN MAKE SURE EVERYTHING FITS AS WE GO. NOW THE NEXT PIECE TO GO ON IS GONNA BE THIS BIG OLE QUARTER SKIN, BUT BEFORE WE CAN INSTALL IT WE'VE GOT TO DO SOME THINGS TO PREP IT, LIKE PUNCH SOME HOLES AND GRIND OFF SOME OF THIS ECOAT.
OF COURSE THESE HOLES ARE GONNA BE WHERE WE WELD THROUGH THE SKIN TO ATTACH IT TO THE CAR. IT'S AS CLOSE AS WE CAN GET TO THE FACTORY SPOT WELD METHOD, AND THIS ECOAT GOES AWAY TO GIVE US A CLEAN SURFACE TO LAP WELD THIS UPPER LIP. [ grinder spinning ]
(MARC) ANOTHER THING WE NEED TO DO BEFORE WE CAN INSTALL THIS QUARTER PANEL IS GET THIS LITTLE CORNER PIECE WELDED ON. NOW THE REASON IS BECAUSE IT WELDS TO THE QUARTER PANEL FROM THE INSIDE, AND IF WE WENT AHEAD AND STUCK THIS ON THE CAR WE WOULDN'T BE ABLE TO GET TO IT. SO I'M GONNA DO THAT NOW.
[ welder crackling ]
(TOMMY) WITH THAT PIECE WELDED ON WE CAN GET OUR SKIN ON THE CAR AND CLAMPED IN PLACE. WE'LL USE THIS QUARTER EXTENSION TO LINE UP THE REAR, FEELING AROUND THE EDGES TO MAKE SURE EVERYTHING IS GOOD. NEXT IS TO START TACKING. NOW IF YOU NOTICE, YOU LOOK AT THE TOP OF THIS QUARTER AND IT KIND OF DOES A WAVE. THAT'S BECAUSE WHENEVER WE CUT THIS THING THE QUARTER RELAXED. THE WAY WE'RE GONNA FIX THAT IS PUSH THIS SIDE OUT JUST A BIT. THAT TIGHTENS BOTH OF THEM UP. NOW WE CAN TACK IT IN, TAKES CARE OF THAT WAVE. WE'LL PLACE THE TACKS A FEW INCHES APART MOVING TOWARD THE REAR. [ welder crackling ] (TOMMY) THE FAR BACK BIT IS STILL BOWED UP JUST A LITTLE. SO WE'LL GENTLY MOVE IT INTO PLACE WITH A BODY HAMMER, BETTER!
(MARC) NOW IS A GOOD TIME TO PLACE SOME MORE TACKS ON THE UPPER JOINT SINCE WE'VE GOT IT LOOKING LIKE WE WANT. [ welder crackling ] (MARC) WE CAN START MOVING AROUND THE PANEL, PUSHING AND CLAMPING THE METAL WHERE WE WANT IT TO BE IN EACH AREA. THEN MAKING OUR ROSETTE WELDS. WE'VE GOT OUR ESAB REBEL IN SMART MIG MODE, WHICH AUTOMATICALLY SETS UP THE WELDER FOR THE MATERIAL WE'RE WORKING ON. [ welder crackling ]
(MARC) AFTER WE WELDED THE PANEL UP, WE'LL GRIND THE VISIBLE AREAS TO MAKE THEM LOOK NICE. [ grinder spinning ] (TOMMY) WELL WE'VE GOT OUR QUARTER WELDED ON AND IT LOOKS PRETTY GOOD. SOMEBODY ACTUALLY EVEN GAVE ME A GIFT, SO I'M GONNA GIVE THEM ONE BACK. THE GIFT THEY GAVE ME WAS THIS TINY DENT WHENEVER THEY DROPPED A PAIR OF VICE GRIPS ON IT. (MARC) I HOPE YOU'RE NOT TALKING ABOUT ME CAUSE I DIDN'T HELP. (TOMMY) YEAH, YEAH, SEE, BUT LIKE I SAID I GOT YOU GIFT, AND YOU KNOW WHAT THAT IS? (MARC) WHAT? (TOMMY) YOU GET TO PUT THE OTHER SIDE ON. (MARC) OH NO! (TOMMY) ABSOLUTELY!
Show Full Transcript
(TOMMY) HEY GUYS, GLAD YOU COULD JOIN US. NOW TODAY WE'RE GONNA BE JUMPING BACK ON OUR '69 DODGE CHARGER PROJECT, AND WE'RE GONNA BE WORKING ON THESE LOWER QUARTERS WHERE IT'S GOT SOME RUST IN THEM. NOW WE'RE EXPECTING TO OPEN UP A CAN A WORMS BUT THAT'S OKAY. NOW WITH THIS PROJECT WE'RE TRYING TO KEEP IT RUNNING AND DRIVING AS MUCH AS POSSIBLE BUT SOMETIMES WE'RE NOT GONNA BE ABLE TO. (MARC) THAT'S RIGHT, AND WHILE TOMMY'S DOING THAT I'M GONNA BE BACK ON OUR BIG OLE MERCURY HERE. I'M JUST GONNA GIVE IT A ONCE OVER SINCE IT'S BEEN OUT ON THE ROAD, AND THERE'S A COUPLE OF LOSE ENDS THAT WE DIDN'T GET DONE BEFORE ITS MAIDEN VOYAGE. (TOMMY) NOW WHILE WE WERE DOWN THERE IN LA, LOWER ALABAMA, WE SAW SOME TELLTALE SIGNS THAT THIS THING LOOKS LIKE IT HAD SOME RUST IN IT, AND THEN THERE'S ANOTHER BACK HERE ON THE BACK TOWARD THE LIP. THE NEXT THING I'M GONNA USE A VERY COMPLEX TOOL. A PIECE OF US CURRENCY, TAP ON THE PANEL. UP HERE SOUNDS LIKE METAL. AS YOU GET OVER HERE SOUNDS A LITTLE BIT LIKE PLASTIC. EITHER WAY A REPAIR NEEDS TO BE MADE FOR THE TYPE OF CAR THAT WE'RE PUTTING TOGETHER. SO WE'RE GONNA DIG IT OUT AND SEE WHAT WE'RE WORKING WITH. I'M GONNA TAKE THIS GRINDER AND RUN RIGHT ACROSS THE TOP OF THOSE LITTLE BUMPERS, AND LET'S SEE WHAT'S IN THERE. [ grinder spinning ]
(TOMMY) YOU CAN SEE THERE'S SOME RUST AND CORROSION UNDER THE FILLER HERE. WELL LET'S GO AHEAD AND STRIP THE REST OF THIS PANEL AND SEE WHAT WE'RE WORKING WITH. WE'RE GONNA TAKE THIS A LITTLE AT A TIME BECAUSE WE DON'T KNOW YET JUST HOW EXTENSIVE THE SINS ARE ON THIS PANEL. IT'S LOOKING LIKE THIS PARTICULAR PIECE OF REAL ESTATE IS GONNA NEED A LOT OF HELP, WITH AS THICK AS THIS MUD IS. YOU'RE REALLY NOT SUPPOSED TO GO OVER AN EIGHTH INCH MOST OF THE TIME, AND WE'RE WAY PAST THAT. WELL THIS OLE CAR'S GOT QUITE A BIT OF FILLER IN IT DOWN HERE. SO WE'RE GONNA HAVE TO CHANGE OUR PLAN OF ATTACK AND STRAP ON ONE OF THESE MASKS. THE FURTHER I GO WITH MY GRINDER THE MORE FILLER I FIND ON THIS THING. LOOKS LIKE THE WHOLE PANEL HAS BEEN MUDDED UP.
WELL IT LOOKS LIKE ALL OF OUR PANEL UP HERE IS GOOD. IT JUST HAD KIND OF A POOR PATCH BACK HERE IN THE BACK, BUT BEFORE I CAN SAY, "WE CAN PATCH FROM HERE DOWN", I ACTUALLY NEED TO STRIP MORE OF THIS QUARTER TO MAKE SURE THAT THE REPAIR DOESN'T NEED TO GO FURTHER UP HILL. [ grinder spinning ] (TOMMY) WELL WE'RE GONNA HAVE TO KEEP CHASING THIS FILLER BECAUSE WE WANT TO MAKE SURE THAT WE DO THE CORRECT REPAIR. NOW SOMEBODY PUT FILLER ON WAY TOO THICK AND WE'VE GOT TO MAKE SURE THERE'S NO HIDDEN SINS UNDER ALL OF IT.
AFTER QUITE A BIT OF ARCHEOLOGY HERE THIS OLE CAR NEEDS A SKIN PUT ON IT. I'M DONE! THE AMOUNT OF FILLER HANGING OFF THE SIDE OF THIS CAR YOU COULD SAY WOULD BE A LITTLE BIT EXCESSIVE, AND A PRETTY GOOD INDICATION OF THAT IS THIS MOUNTAIN OF DUST HERE IN THE FLOOR, AND ALL OF THAT COME OFF OF JUST ONE SIDE. NOW AFTER GETTING IT ALL STRIPPED DOWN WE NOTICED THAT THIS CAR'S HAD A COUPLE OF PRIMITIVE REPAIRS DONE TO IT, AND DOWN HERE ON THE BOTTOM WHEREVER THEY WELDED IT IN THEY WARPED THE HECK OUT OF THE PANEL AND THEN TOOK A HAMMER AND BEAT IT ALL IN TRYING TO MAKE IT BETTER. WELL THIS IS A PERFECT EXAMPLE OF WHAT I'VE SAID IN THE PAST. IT MAY BE BOOGERED UP AND LOOK BROKEN, BUT IT AIN'T PLUM BROKER UNTIL YOU CAN'T FIX NO MORE. (MARC) AND THIS IS HOW WE'RE GONNA FIX IT. WE WENT TO STEPHENS PERFORMANCE BECAUSE THEY'RE RIGHT UP THE ROAD AND THEY'VE GOT THE GOOD STUFF. THIS QUARTER SKIN CAME FROM AUTO METAL DIRECT. IT'S OE GAUGE STEEL, AND LIKE THEIR OTHER PANELS, COMES WITH THEIR RELIABLE ECOAT. THE TOP OF THIS SKIN EXTENDS ALL THE WAY PAST THIS UPPER BODY LINE BY AT LEAST A HALF AN INCH. SO IF YOU DON'T NEED A FULL QUARTER PANEL YOU CAN GET ONE OF THESE AND IT'LL SAVE YOU OVER $200 BUCKS. IT'S THE SAME STORY ON THE FRONT AND REAR OF THE PANELS AS WELL AS AROUND THE WHEEL WELLS WITH THAT EXTRA OVERHANG FOR EASY INSTALLATION.
SINCE WE'RE GONNA BE SLINGING A LOT OF WELDING SPARKS WE'VE GOT TO GO AHEAD AND PULL THE GAS TANK. NO NEED TO TAKE THE RISK OF LEAVING IT IN. THERE'S ALSO A FEW THINGS THAT ARE IN THE WAY AND NEED TO COME OFF, LIKE THE BUMPER, MARKER LIGHT, AND THIS QUARTER EXTENSION.
(TOMMY) WE'RE PRETTY MUCH READY TO START THROWING SOME SPARKS AND THE FIRST INCISION WE'RE GONNA MAKE IS RIGHT HERE ON THE TOP SIDE OF THE QUARTER PANEL ABOUT THREESIXTEENTHS UP, AND THEN WE'RE GONNA COME BACK WITH THAT BIG OLE GRINDER AND WHACK OFF THE MAJORITY OF THIS QUARTER TO GET IT OUT OF THE WAY, AND THEN FOLLOW UP WITH SOME DRILL BITS AND THAT KIND OF THING TO GET THE REST OF IT OFF. THAT WAY WE CAN COVER QUITE A BIT OF GROUND PRETTY QUICKLY. FIRST THINGS FIRST, WE'VE GOT TO MAKE SOME MARKS.
NOW THIS MARK DOWN THROUGH HERE DOESN'T HAVE TO BE VERY ACCURATE BUT WE'LL JUST GO AHEAD AND MARK IT. (MARC) SOME WELDING PAPER IS A GOOD IDEA TO PROTECT YOUR GLASS FROM ALL OF THOSE CUTTING AND WELDING SPARKS. NOW WE CAN BUST OUT THE CUTTING WHEEL AND START GETTING THIS QUARTER OFF.
[ saw cutting metal ] (TOMMY) WE'VE GOT A LITTLE SPOT RIGHT HERE WHERE THEY MANAGED TO WELD THE OUTER SKIN TO THE INNER ONE. SO I'VE GOT TO CUT THAT FREE. [ saw cutting metal ]
(TOMMY) AND WHEN YOU PULL THE PANEL OFF DON'T LET YOUR GRINDER CORD GET CAUGHT ON ITS WAY DOWN.
AH! (NARRATOR) NOW THAT THE BIG PIECES ARE OUT OF THE WAY IT'S TIME TO GET A LITTLE MORE DELICATE ON OUR QUARTER PANEL REPLACEMENT.
(TOMMY) HEY FOLKS, GLAD YOU MADE YOUR WAY BACK. NOW WE GOT MOST OF THAT QUARTER OUT OF THE WAY. NOW WE'VE GOT TO WORK ON GETTING THE REST OF IT MOVED AWAY AS WELL. NOW I'M GONNA USE THIS GRINDER HERE TO DO A LITTLE MASSAGING HERE ON THE BACK SO THAT WE CAN HIGHLIGHT THOSE SPOT WELDS. THEN WE'LL GET AFTER IT WITH A DRILL. TIME TO GET STARTED. [ grinder spinning ]
(TOMMY) WELL LOOKS LIKE WE'VE GOT A SPOT WELD HERE, PROBABLY ONE THERE, RIGHT THERE, RIGHT THERE, AND I'D SAY THERE, POSSIBLY THERE TOO. [ saw cutting metal ] (TOMMY) I'LL USE A BODY SAW TO GET RID OF THIS SIDE PIECE AT THE BACK OF THE QUARTER. IT'S GOING AWAY ANYHOW, AND WITH IT GONE THE REMAINING PIECE WILL BE EASIER TO REMOVE. [ saw cutting metal ]
(TOMMY) NOW WE CAN JUST BUST OUT THE SPOT WELD DRILLER AND GET BUSY ON THIS TAIL PIECE. YOU CAN DO THIS WITH A DRILL TOO BUT IT TAKES A LITTLE MORE PATIENCE. WHEN YOU GO TO SEPARATE THE PIECES YOU MIGHT FIND ONE OR TWO MORE WELDS. JUST TAKE CARE OF THEM IF YOU FIND THEM. WELL YOU GUYS GOT TO SEE THE TECHNIQUE THAT I'VE GOT TO APPLY ALL THE WAY DOWN, FORWARD, AROUND THE FENDER WELL, AND UP TO THE DOOR. SO IT'S TIME TO GET BUSY.
[ grinder spinning ]
(TOMMY) WE MADE SOME PRETTY GOOD PROGRESS PREPPING FOR THE NEW QUARTER SKIN. WHENEVER I MOVE DOWN HERE TO THE BOTTOM OF THE QUARTER PANEL I NOTICED SOMEONE HAS DONE SCREWED UP THE INNER STRUCTURE AS WELL. IT'S GOT QUITE A BIT OF RUST RIGHT IN THROUGH HERE. SO THAT MEANS THIS PIECE IS GONNA HAVE TO BE REPLACED AS WELL. [ air hammer vibrating ] (MARC) THIS OLD COATING HAS TO BE REMOVED TO GET TO THE METAL, AND THE AIR HAMMER WILL HELP GET THAT DONE.
THEN IT'S MORE QUALITY TIME WITH THE BODY SAW. IF YOU'RE GONNA BE DOING MUCH PANEL WORK ONE OF THESE SAWS LIKE THIS ONE FROM MATCO IS JUST ABOUT THE HANDIEST THING YOU COULD HAVE. (TOMMY) GOING THIS DEEP INTO THE REPAIR IS A NECESSARY EVIL BECAUSE YOU DON'T WANT TO BUILD A HOUSE ON A BAD FOUNDATION, AND IF WE JUST REPLACED METAL OVER THE TOP OF THIS STUFF THIS INNER METAL WILL CONTINUE TO DETERIORATE. WELL WITH THAT OLD PIECE OFF THAT EXPOSED SOME MORE BAD NEWS, BUT THAT'S ALL RIGHT. WE'RE GONNA HAVE TO JUST KEEP DIGGING ON THIS OLE CAR UNTIL WE'RE STANDING ON SOLID GROUND. [ grinder spinning ]
(TOMMY) WELL WE GROUND OFF ALL THAT FILLER AND ALL OF THAT STUFF WAS PRETTY MUCH A PERFECT EXAMPLE OF BURYING BAD BODY WORK OR BAD METAL WORK. THERE WAS REALLY NO REASON FOR THAT STUFF TO BE THAT THICK IF IT HAD DONE PROPERLY. SO WHAT WE'RE GONNA HAVE TO COME BACK AND DO IS CUT ACROSS HERE RIGHT AROUND THIS BAD PATCH, AND THEN KIND OF MOVE FORWARD FROM THERE. THERE'S NO REAL REASON WHY TO REPLACE THIS ENTIRE TAIL PANEL WHENEVER WE CAN MAKE A CORRECT PANEL REPAIR RIGHT HERE AND THEN ADD IN THAT NEW CORNER. [ saw cutting metal ]
[ drill spinning ] [ air hammer vibrating ] [ grinder spinning ]
(NARRATOR) AFTER THE BREAK, SEE HOW TO FABRICATE ONE OF THOSE TRICKY CORNER PIECES.
(TOMMY) HEY GUYS, WELCOME BACK. WE'RE MAKING SOME PRETTY GOOD PROGRESS ON OUR OLE MOPAR HERE. WE STARTED OFF BY CUTTING OFF A MAJORITY OF THAT QUARTER PANEL, AND THEN COME BACK AND GOT RID OF ALL THE TRIMMINGS. NOW AS WE WERE DOING THAT WE NOTICED THAT THIS TRUNK PAN EXTENSION WOUND UP HAVING SOME RUST IN IT AND SOMEBODY HAD BUGGERED IT UP DURING THE REPAIR, AND THEN WE WOUND UP FINDING BACK HERE ON THE CORNER SOMEBODY TRIED TO BURY A WHOLE BUNCH OF BAD DECISIONS. (MARC) HEY MAN, I THOUGHT YOU WERE SUPPOSED TO BE PUTTING PARTS ON THE CAR? (TOMMY) WELL I'VE BEEN TRYING TO BUT I KEEP FINDING BAD SPOTS HERE AND THERE, IF YOU KNOW WHAT I'M SAYING. (MARC) YEAH, WELL IT'S GETTING THERE I GUESS. (TOMMY) HOW'S THAT MERCURY COMING? (MARC) IT'S COMING, YOU KNOW, I'VE GOT A LOT GOING ON. THE WOBBLER SHAFT IS LOOSE, THE GIGGLING PIN'S MISALIGNED, SO I'VE JUST GOT A LOT GOING ON. (TOMMY) I THINK I'M PICKING UP WHAT HE'S PUTTING DOWN, AND IT'S COOL, GO AHEAD, I'LL DO THIS SHEET METAL WORK THAT I KNOW YOU DON'T LIKE. IT'S ALL GOOD. HE'S ONE OF THOSE. THE NEXT REPAIR WE'RE GONNA HAVE TO MAKE IS THIS LITTLE CORNER DOWN HERE CAUSE IF YOU NOTICE IT'S KINDA RUSTY AND THAT EDGE ISN'T EXISTENT ANY MORE. SO WE'LL JUST FAB THAT PIECE UP, NO BIG DEAL. WE ALSO NOTICED WHENEVER THEY MADE THAT REPAIR WAY BACK WHEN THAT THEY SLICED INTO THIS INNER ROCKER. SO WE'LL HAVE TO WELD IT UP. NO, WE'RE NOT GONNA CUT UP THIS NEW QUARTER YET BUT WE ARE GONNA USE IT FOR A TOOL TO HELP MAKE THIS PATCH FOR THIS PIECE. SO WHAT WE'RE GONNA DO IS LAY IT UP HERE AND IF YOU NOTICE, SINCE THAT PIECE IS RUSTY, WE'VE GOT TO MAKE SURE THAT WE HAVE AN ACCURATE PATCH. SO FIRST THINGS FIRST, A PIECE OF PAPER.
NOW YOU WANT TO MAKE SURE NOT TO SLIDE THE PAPER AROUND SO THAT YOUR LINE IS AS ACCURATE AS POSSIBLE. THAT SHOULD GET US WHAT WE NEED.
I'M GONNA CUT THIS JUST A LITTLE BIT BIGGER THAN OUR LINE. THAT WAY I CAN FILE IT DOWN TO SIZE WHEN WE GO TO PUT IT IN PLACE.
ABOUT THAT BIG. SO LET'S MAKE IT JUST A LITTLE BIGGER. GOOD PIECE OVER THERE.
[ saw cutting metal ] (TOMMY) WE WON'T BE ABLE TO MAKE THE ENTIRE THING OUT OF JUST ONE PIECE SINCE THE CURVED PART OF THE LIP WILL HAVE TO BE DONE SEPARATELY, BUT IN THE MEAN TIME WE'LL MAKE AS MUCH AS WE CAN OUT OF THIS ONE PIECE.
WE'LL STICK IT IN A VICE AND USE A BODY HAMMER TO BEND THIS PART OF THE LIP DOWN WHERE IT NEEDS TO BE.
NOW TO MAKE THIS PIECE MATCH THIS OLD PIECE IT NEEDS TO HAVE, WE'VE GOT TO FLIP AROUND RIGHT, YEAH, A LITTLE BIT OF A CURVE INTO IT, AND TO DO THAT WE'RE GONNA KEEP USING THIS VICE. [ hammer tapping ] (TOMMY) THE NEXT THING WE NEED TO DO IS BEND UP A PIECE OF METAL SO WE CAN FINISH OFF THAT LIP THAT WRAPS AROUND. NOW I'VE GOT A COUPLE OF OLD DROPS HERE THAT I THINK WE CAN MAKE IT OUT OF. LET'S SEE IF IT'LL WORK. [ hammer tapping ] (TOMMY) WHAT WE'LL DO IS SHAPE IT A LITTLE, THEN TRIM IT A LITTLE, AND GO BACK AND FORTH DOING THAT UNTIL WE GET WHERE WE WANT IT TO BE.
[ saw cutting metal ]
(TOMMY) THAT'S CLOSE ENOUGH WE CAN TAG THAT DUDE TOGETHER RIGHT THERE. OUR ESAB WELDERS ARE GONNA SEE QUITE A BIT OF ACTION TODAY, AND THIS IS JUST THE FIRST BIT OF IT. [ welder crackling ]
(TOMMY) WITH IT ALL WELDED UP WE CAN TRIM OFF THE EXCESS METAL AND GET IT READY TO FIT THE CAR. WE'LL ALSO GRIND IT DOWN TO MAKE IT LOOK NICE.
YEAH I BELIEVE THAT'S GONNA WORK JUST FINE. I DO HAVE TO TRIM OFF THE TOP AND THE SIDE JUST A BIT CAUSE IF YOU REMEMBER I MADE IT A LITTLE BIT LONG TO GIVE ME SOME WIGGLE ROOM, AND I'VE GOT A LITTLE BIT TOO MUCH RIGHT NOW. SO I'LL TRIM THEM BACK AND THEN ROLL THIS EDGE JUST A BIT TO MATCH THAT CONTOUR. WE CAN BURN THIS THING IN. [ welder crackling ] [ grinder spinning ]
(NARRATOR) STILL AHEAD WE'RE READY TO START BURNING THIS BABY BACK TOGETHER.
(TOMMY) HEY WE'RE BACK. NOW IF YOU GUYS HAVE BEEN WATCHING WE'VE BEEN WHITTLING AWAY AT OUR OLE MOPAR HERE CUTTING OUT SOME OF THAT BAD METAL AND WE'RE FINALLY TO A POINT THAT WE GET TO WELD IN SOME NEW METAL, LIKE THIS TRUNK FLOOR EXTENSION THAT WE GOT FROM AUTO METAL DIRECTION. I WENT AHEAD AND PUNCHED A FEW HOLES IN THIS TRUNK FLOOR SO THAT WE CAN MAKE SOME ROSETTE WELDS TO ATTACH THAT NEW FLOOR EXTENSION, AND THE REASON I DONE ON THIS SIDE IS BECAUSE YOU CAN REACH IT WITH THE WELDER. IF YOU PUT IT ON THE OTHER SIDE IT'S NOT GONNA BE VERY EASY AT ALL. (MARC) BEFORE WE GET TO EXCITED WE'LL CLAMP THIS PIECE FOR NOW SO WE CAN MAKE SURE EVERYTHING FITS AS WE GO. NOW THE NEXT PIECE TO GO ON IS GONNA BE THIS BIG OLE QUARTER SKIN, BUT BEFORE WE CAN INSTALL IT WE'VE GOT TO DO SOME THINGS TO PREP IT, LIKE PUNCH SOME HOLES AND GRIND OFF SOME OF THIS ECOAT.
OF COURSE THESE HOLES ARE GONNA BE WHERE WE WELD THROUGH THE SKIN TO ATTACH IT TO THE CAR. IT'S AS CLOSE AS WE CAN GET TO THE FACTORY SPOT WELD METHOD, AND THIS ECOAT GOES AWAY TO GIVE US A CLEAN SURFACE TO LAP WELD THIS UPPER LIP. [ grinder spinning ]
(MARC) ANOTHER THING WE NEED TO DO BEFORE WE CAN INSTALL THIS QUARTER PANEL IS GET THIS LITTLE CORNER PIECE WELDED ON. NOW THE REASON IS BECAUSE IT WELDS TO THE QUARTER PANEL FROM THE INSIDE, AND IF WE WENT AHEAD AND STUCK THIS ON THE CAR WE WOULDN'T BE ABLE TO GET TO IT. SO I'M GONNA DO THAT NOW.
[ welder crackling ]
(TOMMY) WITH THAT PIECE WELDED ON WE CAN GET OUR SKIN ON THE CAR AND CLAMPED IN PLACE. WE'LL USE THIS QUARTER EXTENSION TO LINE UP THE REAR, FEELING AROUND THE EDGES TO MAKE SURE EVERYTHING IS GOOD. NEXT IS TO START TACKING. NOW IF YOU NOTICE, YOU LOOK AT THE TOP OF THIS QUARTER AND IT KIND OF DOES A WAVE. THAT'S BECAUSE WHENEVER WE CUT THIS THING THE QUARTER RELAXED. THE WAY WE'RE GONNA FIX THAT IS PUSH THIS SIDE OUT JUST A BIT. THAT TIGHTENS BOTH OF THEM UP. NOW WE CAN TACK IT IN, TAKES CARE OF THAT WAVE. WE'LL PLACE THE TACKS A FEW INCHES APART MOVING TOWARD THE REAR. [ welder crackling ] (TOMMY) THE FAR BACK BIT IS STILL BOWED UP JUST A LITTLE. SO WE'LL GENTLY MOVE IT INTO PLACE WITH A BODY HAMMER, BETTER!
(MARC) NOW IS A GOOD TIME TO PLACE SOME MORE TACKS ON THE UPPER JOINT SINCE WE'VE GOT IT LOOKING LIKE WE WANT. [ welder crackling ] (MARC) WE CAN START MOVING AROUND THE PANEL, PUSHING AND CLAMPING THE METAL WHERE WE WANT IT TO BE IN EACH AREA. THEN MAKING OUR ROSETTE WELDS. WE'VE GOT OUR ESAB REBEL IN SMART MIG MODE, WHICH AUTOMATICALLY SETS UP THE WELDER FOR THE MATERIAL WE'RE WORKING ON. [ welder crackling ]
(MARC) AFTER WE WELDED THE PANEL UP, WE'LL GRIND THE VISIBLE AREAS TO MAKE THEM LOOK NICE. [ grinder spinning ] (TOMMY) WELL WE'VE GOT OUR QUARTER WELDED ON AND IT LOOKS PRETTY GOOD. SOMEBODY ACTUALLY EVEN GAVE ME A GIFT, SO I'M GONNA GIVE THEM ONE BACK. THE GIFT THEY GAVE ME WAS THIS TINY DENT WHENEVER THEY DROPPED A PAIR OF VICE GRIPS ON IT. (MARC) I HOPE YOU'RE NOT TALKING ABOUT ME CAUSE I DIDN'T HELP. (TOMMY) YEAH, YEAH, SEE, BUT LIKE I SAID I GOT YOU GIFT, AND YOU KNOW WHAT THAT IS? (MARC) WHAT? (TOMMY) YOU GET TO PUT THE OTHER SIDE ON. (MARC) OH NO! (TOMMY) ABSOLUTELY!