'71 Supercharged Hemi Demon

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74Dusted

Stock Piler of 340's
Joined
Apr 11, 2011
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Location
Lewistown, PA
Another member made me realize, I don't have a thread for this car.

Took me 12 Years to replace a '71 Demon that I let slip away to the junkyard, I was young and had no idea replacement frame rails were available. So my first demon became a Honda or some other import :crybaby:

This one was in rough shape, which made it perfect for this project, since it was pretty much an "unwanted" car by most standards.

The floors were shot, The trunk floor was shot, the subframe was wasted, the quarter panels had 55 gallon drums of Bondo/Body Filler in em, The Slant 6 was missing parts and i had no idea if it even ran, The car had next to nothing in options (Power Steering and an AM Radio) It had mixed & matched parts from various A-Bodies and came with a '71 Duster, a '72 340/833 combo and an A-Body 8-3/4" Rear as a package deal (all for $1,500)

Before the car was even home, I had already decided on an Elephant engine :glasses7: and it slowly changed from a 426/727/8.75" to a Supercharged 426+/833/Dana 60 (undecided on what size engine yet). First thing though, I had other things to do before i could even consider throwing a monster under the hood.

I started at the rear of the car, gave the bumper a kick and it all but fell off :wack: And then i pulled out the trusty Air Saw with a Nicholson Bi-Metal Alloy Hacksaw Blade and started chopping away rusty metal. (this thing will destroy metal FAST! I once cut an entire minivan in half in about 10 minutes) Salvageable metal got the spot welds drilled out with a Spot Weld Cutter. By the way, to anyone who has never had the chance to remove a Demon Tail Panel, it is held on with 100+ Spot Welds (it sure doesn't look like that many, but take the time to stop and count them)


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After annihilating the trunk floor and fugly rear subframe rails, i started to put in my own rails (2.5" wide x 4" Tall)

The rear crossmember is made from metal used to stamp Unibody Frames :thumrigh: My dad bought a huge roll of the stuff at the junkyard many years ago and it works great for this kind of stuff. I only sandblasted the welding surfaces at the time, once the car is outside everything gets blasted.

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Rear Rail (semi clean) with a 3.5" Spring Relocation in the mock up stages. Old worn out bushings in that picture, and a freshly sandblasted leaf spring pack with new spring hangers.

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And the car as it sits at the moment. Flat Trunk Floor, Rear Crossmember, 3.5" Spring Relocation, Tubbing in progress, etc. nothing is "finish welded" (just spot welded, like a normal a-body) at the moment. I've gotta set the car back on its wheels and roll it out of the shop for some serious clean up inside. Also while the car is outside it gives me the chance to go crazy with the sandblaster and take everything to shiny metal, then all the body seams and so forth will get a nice bead of weld.

Then it comes back into the garage to do reinforcements on the front rails. Install subframe connectors, torque boxes, floor pans, additional supports and structural work at the rear rails & crossmember.

After all that, it gets a Rollcage, the Fenderwells removed in favor of the Cage & Tubing (and then a set of plastic wells, like a newer vehicle). I could go on for a long time, but i'll be honest, i'm actually forgetting stuff at the moment. And sorry about the shortage of pictures. It's just myself working on this car, and I only manage to get pictures when i actually remember to do so (and half the time the batteries in the camera are dead anyway :eek:ops: )


Oh? The intended purpose for the car? Strictly a Street Car :p
 
That shop is a mess...........would drive me nuts (OCD here).

Keep hackin that rusty crap away! Oh yeah, the Demon tail panel will never fall of a factory car
 
That shop is a mess...........would drive me nuts (OCD here).

Keep hackin that rusty crap away! Oh yeah, the Demon tail panel will never fall of a factory car

Yeah, the shop needs some serious cleaning before winter sets in. You probably can't tell from the pictures, but it's a 4 Bay/Car Garage with a separate Paint Booth.

Every time i try to clean it up, my grandfather (the boss) stops me and says "You can't throw that out" (example : flywheel for an 80's Furd Escort) "It's a good part, we may need that someday" :wack: So there's literally a mountain of parts for cars that nobody drives anymore, which means all of the mopar parts (example : X Heads, Engines, Fenders, etc) are mixed in with those piles since i can't put them on the shelves.

I cut him a deal though, I would replace the Quarter Panels, Rocker Panels and other rusted/damaged metal on his AWD Caravan on the condition that he lets me clean the garage my way :cheers:
 
Great skills there. I wouldda run from that car.
 
It's a slow moving project, yet my friends seem to think i'm moving along at a blinding pace.

I only work on it during the evenings and weekends, and most of the time I'd rather relax far away from a car, after working on cars all week you don't want to work on your own stuff disgust Today is a slow day, only one vehicle was scheduled, so I feel like working on the Demon tonight/this weekend :D

Rolled it into the garage a couple months ago and i've only worked on it a little bit (recently, except for cutting rusty metal out the first day it was in the garage) With the winter months approaching, i've got a little more drive to work on the car.

Also a big thanks to Oldmanmopar, who sold me the Tail Panel and various other parts for my project, My old tail panel was a total mess and had at least 15 pounds of bondo in it :wack:

I understand that 20+ years ago these cars were common, but man that's no excuse for crappy body work. Some people should put down the snow shovel (that they're using to scoop the bondo with) and step away from the car :D Fortunately, a nice 40 Grit disc on the D/A gets rid of 40 years of previous owners in a hurry (1 grit for each year, lol), and what that doesn't touch, the Sandblaster will, or when all else fails : Air Saw, Air Shears and Grinders :D
 
Wow you really have a major project. I am following this one. Thanks 74 Dusted
 
An ambitious project to say the least,but it looks like you've got a good jump start on it !!Keep up the good work,I'm sure you'll appreciate it more in the end !!:cheers:
 
Picked the car up with the engine crane and rolled it backward to provide some more room up front (it was tight against the garage door)

Warning, the following pictures are extremely graphic... So if you have impressionable little a-body fans saying "daddy, what you reading?", make them leave the room. Also you may want to fetch a bucket to puke in, because this is some nasty stuff you're gonna see...



Well, I warned you, scroll down.


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Told you it was nasty, who just threw up? raise your hand :D Anyway, it's no big deal, just some rusty metal. I had already planned for this and have a set of rails to match the rear on hand. First thing's first, get the baby level, squared and install a jig to hold everything in place (and pray) and then drop the K-Frame for some massive rust removal and frame rail replacement.

Once that's all done, it gets a Modified '73 K-Frame & Brakes, The fenderwells get knocked out and the starting point for the Cage will begin, along with Coilover Towers/Brackets
 
I wish I knew you when I had my 65 Barracuda you could have given me advise to save it. But you have your job cut out for you with this car.
 
This is actually my first time at doing such an expansive project too, I just swing in the dark and when someone yells "sunuva!" i know i'm going in the right direction:D

On another note, I am beginning to loathe spot welds, everywhere i look there's more of them i need to remove :banghead: Oh well, it's all part of the fun.
 
In the pic of the /6 ,why are the heater hoses exiting the fenderwell? Great job.


maybe just an illusion.
 
did you find that demon in a river or something Im from vegas not much rust out there but if you got a plan Im sure you can fix it good luck.
 
did you find that demon in a river or something Im from vegas not much rust out there but if you got a plan Im sure you can fix it good luck.

Nah, that's just typical Pennsylvania rust. They dump so much chemicals on the road in the winter, it rusts the vehicles out.

Yep, already working at fixing the front end, gotta love 40 years of rust, nothing wants to come loose. Like the adjusters on the Torsion bars, there's no threads left on them, just a big goober of rust :banghead:


- Dartfastback, The heater hoses are just laying on the fenderwell, a previous owner chopped the hoses off at the firewall and at the engine too (why i don't know). So it's an optical illusion that makes them look like they're going through the fenderwell.
 
Not much of an update, My ring finger is getting in the way of working. No it's not weighed down with a chunk of metal. I was changing the bit in the drill press and the chuck slipped as i was tightening it. Raked my hand down across the side of the drillbit. Who would have thought you could slice a finger to the bone with a drillbit that wasn't spinning :eek:ops:

Slapped the finger with some of that glue in a spray can (the kind they use in the ER) and after some arm twisting from some family members, actually went to the ER. Where they proceeded to give me a tetanus shot and a prescription for antibiotics to keep the finger from getting infected. Didn't bother to stitch it, since i had already glued it. (interesting, i'll have to remember that)

Did manage to drop the K-Frame, Engine & Transmission and get some measurements to start making new Control Arm Tabs/Mounts. Made 3 of the 4 Tabs (for the Driver's Side) so far. Also got a closer look at the frame on the passenger side, it's in slightly better condition than the driver's side, but i'm still cutting it all out for new metal :D

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Sorry you got hurt.The sub frame does it look worse than it actually is?
 
Eh, getting hurt is part of the experience of working on old stuff. The irony is, i got hurt working on the Demon, and when they gave me the Wrist Band/ID Band at the ER.. My ID Number was 666 :finga: To make matters worse, the car is also named Lucille (Devil's Daughter..hehehe), anybody getting goosebumps? :D

The subframe is nasty, that's for sure. Wherever you grab it or tap on it, a hole pops up. The passenger side rail isn't quite as bad as i was expecting, it's a far cry better than the driver's side rail (only a few holes up in the wheelwell area). Underneath the car/floor though it's still pretty bad though.

It's ok though, I have a set of rails ready to go in the car. The only piece of frame that will remain untouched, original is a short stubby section at the front where the bumper mounts bolt on :D It's about the only piece of frame that's solid, so it'll get sleeved/capped with the new rail (after cutting off the bad frame section behind it). I just have to finish welding in the reinforcement plates and "nuts" that the K-Frame bolts go through and finish the Control Arm tabs/mounts before i can start installing the new rail on the driver's side.

Once the Front Subframe is done, then i get to move on to the Torsion Bar Crossmember/Transmission Crossmember, Have the materials for that too.

When i'm done with the front rails, I'll let you guys know what they were originally designed for/removed from (and you probably wouldn't believe it). Until then, it's a surprise :D

Basically there's no original metal left underneath the car, or at least there won't be when i'm done.
 
Thanks. I look forward to seeing more,and see how everything is done.
 
The unfinished front subframe, can anyone guess what it was originally from?

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Dodge Caravan, which is why there are so many plug welded holes on the frame, Dodge had tons of holes in those frames for optional stuff and mounts, which were of no use on the Demon.

They also worked great to weld to the Inner Reinforcement Plate, Control Arm Mounting Plate, and K-Frame Mounting Plate. The 1/4" Plate that the Control Arm Mount Tabs are welded to, will bolt into the Rollcage and Upper Shock Mount. It is also part of the Rear K-Frame Mount/"Nut" Plate inside the Subframe.

The Subframe is 4" x 2.5", except at the Control Arm, where it necks down to 3" x 2.5" for Upper Control Arm Clearance. I still have some more work to do to it, it's far from finished, and then i've gotta clean everything up nicely. I also added a Plate from the Frame to the Wheelwell near the firewall, after browsing through some topics here on FABO, it seems that the reinforcement there is a good idea to reduce flex/twist.

Overkill? Sorry, I'm not used to fabricating stuff for cars. My experience is mostly with Plow Trucks, Industrial/Agricultural Equipment, Dumptrucks, Backhoes/Dozers, etc.

Heavy? Probably, I'll be going with a 'Glass Clip and Aluminum Heads to try and knock some weight off the front suspension. Although "Hemi" and "Weight Savings" usually don't get used in the same sentence :eek:ops: :D
 
Wow man that is quite an undertaking bringing this one back from the dead. All the credit due to you my friend, great fab work!!
 
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