OzzieMozzie's Valiant Charger Project

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Hey gang ! Here's some pics of the boot (trunk) gutter repairs.
As you can see the original corner piece incorporating the drain pipe was rusted out.
Bootgutter010.jpg


I went to a sheet metal fabrication mob and they told me they couldn't fold up the pieces I needed because the folds were too small, so I made them up myself in the vice.
Bootgutter001.jpg


Bootgutter002.jpg


Bootgutter004.jpg


Bootgutter009.jpg


Bootgutter013.jpg


Bootgutter015.jpg


Bootgutter016.jpg


Bootgutter019.jpg
 
Man you sure had your work cut out for you!

Any idea how many hours youve put in it so far!!?
Stil didnt say what motor you wanna or going to put in it...
 
nemesis said:
Man you sure had your work cut out for you!

Any idea how many hours youve put in it so far!!?
Stil didnt say what motor you wanna or going to put in it...
Click to expand...
All up so far it's taken me about 300 hours, I did say earlier up this page that I'm going for a mild 318/904 combo, you must've missed it in amongst all the pics. lol.
 
Next I removed the diff and front suspension and crossmember to put it up on the rotisserie only to find more rust in the chassis rail around the steering box area (common problem). So I got it up on the rotisserie and decided before I cut the rust out of the rail that I would weld a support brace either side of the area I was going to remove, just to be sure there was no movement.
Here's some pics.
chassisrail007.jpg


chassisrail008.jpg


chassisrail005.jpg


chassisrail006.jpg


chassisrail010.jpg
 
Impressive, you got some amazing skills.
Keep up the great work and keep the pics comming.
 
When I removed the rusty section of rail only one reinforcing gusset was intact, so I had to fabricate new ones out of 3mm plate.
chassisrail012.jpg


chassisrail011.jpg

Here's some pics of the new rail section I also fabricated out of 3mm plate.
chassisrail013.jpg


chassisrail014.jpg


chassisrail015.jpg


Reinforcing gusstets welded in place.
Chassis001.jpg

Rail section welded in place
Chassis003.jpg


Chassis007.jpg


Some more pics of the main reinforcing gusset with the crush tube fitted, prior to fitting the rail.
Morechassisrail001.jpg


Morechassisrail002.jpg


Morechassisrail004.jpg


Morechassisrail003.jpg


Morechassisrail005.jpg


Morechassisrail006.jpg


That's the stage I'm up to at the moment, so now you're all up to date. I've got a mobile sandblasting guy coming around tomorrow to give me a quote to blast the undercarriage, engine bay, front suspension parts, diff and inside the bolt on panels. It won't be getting done until next month so I'll update again then.
 
OzzieMozzie said:
All up so far it's taken me about 300 hours, I did say earlier up this page that I'm going for a mild 318/904 combo, you must've missed it in amongst all the pics. lol.
Click to expand...

Oh ok cool!

Well i cant wait til its finished!
I wish i had the skills you have.

Instead im goin to have to reach in deep into my pockets
to restory my vj charger :(
 
I am truly amazed at your perseverance. I've welded a couple of panels in my car, but nothing like this. I enjoyed the pictorial sequence. You will have a very nice car when completed.
 
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