The Darwin Project

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Darwin

Evolutionary Member
Joined
Aug 21, 2009
Messages
353
Reaction score
6
Location
Muskego WI
66 Cuda /6
The resto is well under way. For those of you who didn't catch my intro in the welcome wagon a few weeks back heres a little background. My name is Bob, the car is dubbed Darwin by my 15 year old son Nick for his theory of evolution, chebby eats ferd, Barracuda eats Chebby.
I've owned this car for about 5 yrs. Not my first A body, I've owned several over the years, my first car was a 65 Dart Wagon 273 Auto, wish I still had it. Had a couple Darts, A Volare and a couple Dakotas since. Still have a 97 Dakota that my 19 yr old son Ryan fell in love with (I think its his girlfreind) treats it like a baby. Now that hes gone to school I get to drive it again. Anyway, Nick and I (and Ryan) started on this project in June this year. Was supposed to be a "simple" cosmetic restoration. We were just going to lift the engine, clean up the bay and replace any neccessary mechanicals and put it back in. Next on the list was a disc brake swap, want a safe ride as this is going to be Nick's first car, got a complete 73 dart set up from a guy in Arkansas, nice stuff. We blasted rebushed and painted those parts and they're ready for installation. Nick found a 7 1/4 LBP rear end to go with the disc setup on the front so that should be an easy swap. I've got a set of Magnum 500's that I had on the Volare so we got those blasted and painted.
Orderded new window rubber so when its ready for paint we can pop the glass and we'll be good to go. Now to the interior, heres where "simple" left my vocabulary. The seats, door panels and trim are in excellent condition, just needs carpet. Simple, we'll just pop the seats out, replace carpet and move on. Oh contrare. Finally got the got front seats out and only managed to break one bolt, the other seven got cut off with the die grinder. After removing the sill plates, kick panels and such, started pulling the carpet and Nick says to me "dad, the floor seems a little squishy". After further review, it seems a little gone. Pulled out the rear seat and found one of many mouse nests, I think this thing was the rodent hotel, they had stuff everywhere, glove box, kick panels, headliner, rusted out frame rails, everywhere. So as it goes, the "simple" resto is now a shell. All in one months time, then on July 5th Nick broke his leg and that put the project on hold, without the son its not a father son project. Well he's finally off the crutches, still in a boot, but able to work on the car again. This is getting a bit wordy so I'll let the pictures tell the story from here. I'll keep you posted on the progress and any input from the great FABO family would be greatly appreciated.

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AAAGHHHH Rust!
Cool car, sorry about the rust. It does look like you have it well under control. I'm going to be watching real close! Got 1 going too!!
Good Luck & the main thing is to enjoy the time being spent together. Before you know it they move away and get too busy for you!!!
 
Very nice! FYI I noticed there is a NOS front bumper on ebay, hard to find one for a '66...
 
Thanks 64dart. So far we're really getting in to it. Thats my son in the last two pictures, first time welding. I try not to work on the car with out him, hard for me sometimes as I really enjoy projects like this.
 
Cool project and cool name. You need to use one of those Darwin fish with the legs for your avatar. But change the legs to wheels!
 
You will want to shield all of the glass in the car while welding,hopefully not to late...the welding spatter will stick into the glass
 
Thought I'd give you an update. Been under the weather the last week or so.
Finally got to fixing the torsion bar mounts. Got the kit for both sides from Auto Rust Technicians autorust.com nice people there. Put the order in on a Thurs., they said they didn't have any in stock and would have to make me a set, probably not til mon. or tues. the next week and with shipping time i wouldn't see them til the following week. Got them dropped at my door within a week. Now thats service. Got them in the car today and finished welding. I'm not going to get my welding certification based on this job, but I don't think they're going to fall off on the first bump either. Don't have the front floors in yet, figured it would be easier to fix the torsion area with them out. Now that the torsion bar mounts are done the floors will go in this week.
While I had it in the air I decided to scrape the scaley rust and flaking undercoat. Not fun, as I'm sure most of you know, thats what kids are for. I set Nick up with a couple scrapers and a wire wheel on an air drill and told him to have at it. Well, together, it took us about 3 hrs. Not looking for perfection, just want to get the major crud off. I plan on coating most of the underside with POR 15, then reundercoating. More later.

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Hello Bob :cheers:
Good to hear Nick's doing good and getting to help in this great father son build :happy10:
Nothing is better then to see a father son working together and enjoying this great hobby , Keep up the good work and I must say you are moving right along. Tell Nick I like the name and I bet he is a good hard worker.:cheers:
Thank you for sharing this build with us Darwin (Bob):cheers:
 
Been working long hours this week, finally got to work on the car alittle.
We coated all the rusty areas on the underside with POR 15. The plan was to finish the front floors and patch a couple smaller holes in the floor, but due to limited shop space thats on hold. Decided to tackle front suspension instead. I knew the left front frame rail would need some reinforcement due to visible rust thru around UCA mounts. I unbolted the steering box and pulled aside to discover some major rust thru on rail. Went ahead and removed shock and UCA to find non-existant frame rail at rear UCA mount, top of frame rail is gone and rear UCA mount is not even attached to frame at all. Went ahead and cut out top of frame rail, cut off upper bump stop and brake line mount. I'm going to plate top and both sides with 1/8" steel plate and with some careful measurements try to determine exact UCA mount location. I'll have to fab a new UCA mount 'cause all thats left of the rear one is the slotted washer for the bolt to go through. Once I get that fixed I'll get back to finishing the floors. I'm changing the front suspension to later A body disc brake set up, but for now I'll just put the drums back so I can roll it around the shop.
I'm hoping to get it on all four again soon. My goal is to have the body and paint done by xmas. (UGH! thats only seven weeks away) and I still need to fab a new rear cross member and repair a small hole in the rear corner if the trunk. Wish me luck.
 
Another rough week at work, finally got back to the fun stuff today. Here are a couple of pics of the underside after the POR 15 was applied.

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Spent about 4 hrs today fixing the left front frame rail. Had to plate the rail inside, top and outside. As you can see the rear UCA mount was completely gone. I salvaged the excentric and made a new mount, I'm also reinforcing the other mounts. I finished welding the plate on the inside of the frame and patched a rust hole in the inner fender. Got the top plate pretty much done and the outside plate is tacked in for now, I'll finish welding tomorrow. Hoping to get the steering box back in so I can get it on the ground and get back to finishing up the floors.
 
Got the floors in and welded. Patched a small hole in the trunk floor right above the bumper mount, thats the only rust in the trunk area. A little grinding and seam sealer and I can start prep on interior for paint. Reinforced the rear cross member, it was rusted pretty thin around bumper mounts. Used 1/16th" steel plate, didn't want to go too thick 'cause that might pull the bumper out away from the body.
Took a break from welding and started sanding on the left rear quarter panel for about an hour.
I'm gonna try to get it sanded ironed out and into primer by thanksgiving.

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We've made some pretty good progress on the body since my last update.
Mocked up the rear bumper to get propper spacing between body and bumper, it may need some shimming and such later, but I think we're in good shape there.
Finished the grinding on the floor pan, ready for seem seal and paint.
I called in a freind in the glass business to remove the windshield and rear window. Kind of wish I didn't have to remove the rear window, it had a really good seal and was a real bear to get out, but there is no way to get a good paint job without removing it. Somewhat to my surprise, there was no rust around either window. We then removed the headliner.
I will be removing the dash soon to either replace the cracked dash pad or possiblely go custom and smooth the dash and go without a pad. Opinions?
We decided to shave the letters off the trunk and hood along with the side script emblems, radio antenna and fender turn signal indicators. I don't want to misslead anyone here, I've solicited the help of a professional to help, teach, do the body work. Nick and I get there as often as we can to learn as much as we can. This is a guy that I've been doing business with for the last 30 yrs or so. So nick and I do the rough stuff (welding, grinding, patching, etc) and pretty much let him do the stuff everyone is going to see. I'll let the pictures tell it from here. We're still planning on having the car in primer this week.

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My goal was to have the car in primer by thanksgiving.
Got the car in primer today. Thanks to my two older sons being home from collage.
Seam sealed the floor and coated it with an undercoat that will dry to a plyable semi hard finish. This will help any pin holes that might have been missed and also help prevent the seam sealer from drying out and peeling later.
Pulled the dash and removed the dash pad, which will not be going back on.
I like the look of the smooth dash so I'm going to fill the dash pad holes, and paint the same color as the exterior along with the rest of the hard surfaces in the interior, only I will use a satin clear on all interior peices.
Cleaned and prepped the engine bay, ready for a coat of sealer.
After hours of filling, sanding, filling and sanding some more on the body we shot it with a thin coat of sealer primer. With the whole car in primer you can really see any imperfections, so after going over the entire car, a little more spot filler and minor sanding it was ready for a good coat of sanding primer. Thats what you see in the pics.
Next on the docket is to seam seal the underside of the floor and undercoat
the entire underside with the same thing we used on the interior floor.

Happy Thanksgiving everybody!

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Got the bottom side seam sealed and undercoated. Decided to go with a different product for the underside than what I used on the inside floor, Wurth undercoat and sealant. Coated everything from the cowl back, hopefully will help fight the nasty Wisconsin weather although I have no intention of driving it in the winter.
Next up is to start block sanding the body and prep the interior trim pieces for paint. If all goes well, should be ready for some color by the end of the week.

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Seal Primer and painted the firewall, inner fenders, core support and k member.
Painted the underside of hood and trunk and also inside trunk and door jambs.
Next we'll be fitting the hood and trunk and aligning the front fenders which were removed for rust repair.
Once the body panels are in place we will block sand with 400 and search for any imperfections, repair as necessary and wash the car and wet sand with 600. Wash again, search for imperfections, repair as necessary, let dry overnight and we should be ready for paint.

What do you guys think of the color?
For you Mopar purists; Please don't shoot me for not choosing a Mopar color. Its a Ford color, med. platinum. I thought it would compliment the stock dark blue metalic interior which will be going back in.

Hope to have pics of car in paint tomorrow.

Bob

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"What do you guys think of the color?
For you Mopar purists; Please don't shoot me for not choosing a Mopar color. Its a Ford color, med. platinum. I thought it would compliment the stock dark blue metalic interior which will be going back in."

Hey, mine is a Jaguar topaz (paint by Sikkens)! Love the color, the combo should look awesome. Keep up the good work!

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