65 Dart Wagon Conversion to a Sedan Delivery

[65 Dartman]

My sandblaster guy called and said he was able to “repair” his air/sand mixing valve and could come by next week to finish the inside and all the jambs. The jambs on the tailgate will have to wait till I make a temporary harness to raise the window to remove it.

I Am getting pretty antsy looking at that white canvass in the engine compartment. So what’s an antsy fellow to do - maybe see how some things will look (or maybe even install them?). I painted the the battery tray earlier this year so that would be a good starting point. I did forget to install some old bolts where the tray bolts up and not having chased them, that was the first starting point (memo to self - install old hardware in any fasteners to avoid getting paint in the threads and having to chase them). Once they were cleaned out and the threads on the bolts cleaned up, everything bolted together nice and smooth. Then I spotted my AC drier bracket previously powdercoated by Leanna @CudaChick1968 and looking just like I received it way back when. Two bolts through the predrilled holes I did at least 10 years ago, 2 nuts and it’s done. Got a feeling everything against that WW1 white paint is gonna pop! As Ulf @65dartcharger keeps saying, the fun stuff is gonna begin!

 

[CudaChick1968]

It's gonna be awesome Don! Keep us posted! Thanks for the shout out

 

[65 Dartman]

Didn’t do a darn thing today but did receive in the mail some cad plated stuff for the tailgate area and a couple of black phosphate coated screws/bolts for the licence lamp assembly. The 2 small brackets on the lower left mounts on the tailgate jamb area on the body while the pair of latches on the right mount to the tailgate itself. It was fun disassembling a spare rotted out tailgate to retrieve these (Not!). At least it will be easier to disassemble/reassemble on the tailgate going in the car now that I know what to expect!

 

[JDMopar]

That stuff looks good. I'm pretty lucky, that there is an industrial metal finishing place where I live. I can walk in with stuff in sandwich bags labeled with what finish I want, and they will work it in with runs of other stuff for me. Nitty gritty details like that make a HUGE difference in the finished product of our old cars!

 

[65 Dartman]

Agree that the details do make a huge difference in the finished product. Ulf @65dartcharger is my inspiration for doing it this way and using the correct finish on all the nuts, bolts and other hardware.

 

[65 Dartman]

Did get the epoxy primer on the inside firewall, all 4 floors and under where the rear seat goes (No pics) AND in white paint (pics below!).

Well, I screwed up big time! What I forgot to do was seam seal all the bare metal on all the seams and welded areas. I just plain forgot in my haste to prime and paint it. I am using Eastwood’s brushable seam sealer which recommended if painted, scuff it up. So i tried a wire brush on my drill and scuffed up the paint - except it it wasn’t doing diddly. So got the Rolox out with 36 grit and went to town removing paint and primer right down To bare metal any welds/seams like I should have done in the first place. The Eastwood brushable seam sealer looks just like the seam sealer the factory used when brushed on - except It now looks and Has better coverage than the factory job (which looked like a hit and miss job). Now I KNOW it was done right compared to OEM. Now I’ll hit it with the white paint next time any is done

 

[65 Dartman]

The sandblaster guy called this morning to see if I was ready for any more blasting as he was in between jobs - yes - the lower rear side panels, spare tire area, both rear wheel wells and if possible both door jambs on the body. All I can say is sand gets everywhere! I haven’t kept track but this seems like the 3rd or 4th time the inside will be cleaned out! I remembered this time - all seams in the rear and the rain gutters all got seamed sealed. everything he blasted is now covered in epoxy primer!

 

[65dartcharger]

The sandblaster guy called this morning to see if I was ready for any more blasting as he was in between jobs - yes - the lower rear side panels, spare tire area, both rear wheel wells and if possible both door jambs on the body. All I can say is sand gets everywhere! I haven’t kept track but this seems like the 3rd or 4th time the inside will be cleaned out! I remembered this time - all seams in the rear and the rain gutters all got seamed sealed. everything he blasted is now covered in epoxy primer!

Sand gets everywhere!

 

[65 Dartman]

. . . . all seams in the rear and the rain gutters all got seamed sealed. everything he blasted is now covered in epoxy primer!

And this afternoon the spare tire area is shiny white paint,

as is both body door jambs, (just passenger side shown):

and both front fenders on the inside:

Also painted was the passenger door jambs not seen when the door is closed (forgot to take a pic).

I need to see if the sandblaster guy can come by tomorrow morning and do the driver’s door jambs and inside of the front valence. Getting a bit closer everday!

 

[65dartcharger]

And this afternoon the spare tire area is shiny white paint,

View attachment 1715600354

as is both body door jambs, (just passenger side shown):

View attachment 1715600357

and both front fenders on the inside:

View attachment 1715600358 View attachment 1715600360 View attachment 1715600356

Also painted was the passenger door jambs not seen when the door is closed (forgot to take a pic).

I need to see if the sandblaster guy can come by tomorrow morning and do the driver’s door jambs and inside of the front valence. Getting a bit closer everday!

It really is coming together fine! It will be like a factory one of none produced!

 

[65 Dartman]

It really is coming together fine! It will be like a factory one of none produced!

Chrysler should have done it as Ford had the Falcon sedan delivery. They probably looked at returns versus cost and figured there would not be enough buyers. Oh well, i will have that 1 of none; it definitely will be more plush and luxurious than a factory sedan delivery would have been!

 

[65 Dartman]

I need to see if the sandblaster guy can come by tomorrow morning and do the driver’s door jambs and inside of the front valence. Getting a bit closer everyday!

The sandblaster guy showed up at 10 and was finally setup by 11.

EDIT: I was a little perturbed that he was taking so long to get set up - like he was moving in slo-mo and me paying by the hour at that!

Anyway he got the driver’s door jamb , the inside of the front valance, and a bunch of small stuff sandblasted. I won’t need him back until I can remove the glass and other stuff from the tailgate. Everything got epoxy primed AND painted white. As soon as I get the upper inside of both doors painted light metallic blue, they’ll be ready to hang and adjust. After that the fenders, front valence and hood gets installed and aligned in prep for final blocking and paint. Getting close!

 

[65dartcharger]

The sandblaster guy showed up at 10 and was finally setup by 11.

EDIT: I was a little perturbed that he was taking so long to get set up - like he was moving in slo-mo and me paying by the hour at that!

Anyway he got the driver’s door jamb , the inside of the front valance, and a bunch of small stuff sandblasted. I won’t need him back until I can remove the glass and other stuff from the tailgate. Everything got epoxy primed AND painted white. As soon as I get the upper inside of both doors painted light metallic blue, they’ll be ready to hang and adjust. After that the fenders, front valence and hood gets installed and aligned in prep for final blocking and paint. Getting close!


View attachment 1715601000 View attachment 1715601001 View attachment 1715601002 View attachment 1715601003 View attachment 1715601004 View attachment 1715601005

It looks awesome Don!

 

[65 Dartman]

My bodyman friend just happened to stop by while I was starting to mask the white on one of the doors in prep to paint the upper door frame and upper inside panel. I wonder if my wife just happened to call him! Then he noticed the inside panels had gray epoxy primer on them. His comment - “I suppose you think you gonna paint the inside as well”. Well, yes to that. Told me to stand back and let a pro do it. Zip zip zip he got everything masked, scuffed as needed and in blue metallic paint that matched to original inside paint perfectly. Yes, he is a lot quicker than I am so I really appreciate his help

Driver’s side from the passenger door

Passenger side from the driver’s door

Driver’s door

passenger door

Now that the doors are cut in on the jambs and inside done, they can be hung and aligned. I will need his help as my lovely helper (the wife) doesn’t have the horsepower to do this

 

[75slant6]

Full disclosure, I’m not a big fan of the early A wagons. Just never liked the styling of the rear doors and rear side windows. Now that said, you fixed all those “issues” by making it a 2 door panel wagon. Therefore, I’m really liking this car! You’re doing a fantastic job. I’ve enjoyed following along

 

[RustyRatRod]

Don, this thing is really starting to look like somethin! I am likin it a lot.

 

[65 Dartman]

Full disclosure, I’m not a big fan of the early A wagons. Just never liked the styling of the rear doors and rear side windows. Now that said, you fixed all those “issues” by making it a 2 door panel wagon. Therefore, I’m really liking this car! You’re doing a fantastic job. I’ve enjoyed following along

You are correct on the styling since basically the factory took the 4 door sedan, added the ribbed roof and filled in the quarter area with glass. If they had done something different with the quarter glass, like make it straight and reworked the D pillars to match, it might have looked better. My rear side panels follow the same contour of the glass in the back but IMO is more esthetically pleasing - just my opinion!

 

[65 Dartman]

My conversion from a 4 door wagon to a 2 door sedan delivery (or also called a panel wagon) has required me to learn or brush up my knowledge on a bunch of skills. In addition to being a metalworker, engine mechanic, and automotive electrical engineer, i find that I also need to be somewhat of a woodworker. The spare tire cover was made of true 1/2 inch rough finish plywood painted gray. B Body wagons had sone kind of protective cover - linoeum? Painted plywood was what you got in the early A wagon. This is the side that was seen in the car and it’s in rough shape with parts of the plywood peeling and just plain gone.

I was looking at some true 1/2 inch sanded plywood (not the 15/32nd rough plywood) at Home Depot. My banker asked what I needed it for, a second later the light went on and she said “for that wagon?” It was actually less expensive than the rough stuff. As soon as I pick up a suitable jigsaw blade so as to make a nice smooth cut, that part of the puzzle will sort of be done.

Because I won’t be hauling anything except maybe a cooler, my plan is to cover the whole back area from the back of the Barracuda folding seat to the tailgate in carpet that matches the color and texture of that in the front. I was able to buy sufficient carpet yardage through Stock Interiors to do the job.

 

[65 Dartman]

I finally finished the front to rear wiring harness using the original wagon harness as the basis for a few modifications.

Because this wagon had a manual rear window, I Had to fabricate the power rear window harness using 12 gauge wires as per original. I decided to add it to the main harness even though they were separate harnesses since most wagons got a manual rear window. The wires with the white connector as seen from top to bottom is semi original with the purple wire for B/U lights, red is now for brake lights, black for taillights, brown for left turn signal and green for right turn signal. The wires with the black connector is for the tailgate power window. The blue and white wires in the gray connector is for the gas sending unit.

I am using a Dakota Digital instrument cluster and the instructions for the gas gauge recommends a separate ground from the sending unit to their control box spiral wrapped with the sender wire

This mess is the way if came out from under the bracket supporting the spare tire cover. I added the new red brake wire that connects to the left and right outer tail lights and to a 3rd center-mounted roof brake light. Separate Brake light and turn signal Wiring mods will be done at the brake light and turn signal switch wiring

And then wrapped everything except that ness in the non-sticky harness tape.

 

[65 Dartman]

Well, bad news #1. the tailgate rear window motor is locked up tighter than a bull’s azz! Tried with an external factory switch and the tailgate key switch and nothing but a little buzz.

More bad news #2 - the window is in the Full down position, making it impossible to get to the fasteners holding the window retaining frame to the arms.

Bad news #3 - to get everything removed from the inside, I made the painful decision to break the window, which I did!

Bad news #4 - see the 2nd paragraph of good news #2

Good news #1 - I have a spare rear window from the original Non-motorized tailgate.

Good news #2 - got the frame with the motor on it, the wiring harness, DODGE letters and 3 pieces of trim out. The wiring harness needs checking and re-wrapping at a minimum. Found that a previous owner of this particular tailgate had been inside at some point as the tailgate tail light wiring had been “Adjusted” so they were non-functional.

Other than the latch assembly parts and torsion bar, the tailgate is ready for sandblasting, several dent repairs, and welding stress cracks in both upper external AND internal corners

One of several dents:

Driver’s side upper

Passenger side upper

I checked with DMT and they don’t carry the wagon’s tailgate upper glass seal. Looks like I’ll need to fabricate it with some bulk catwhisker material.

 

[JDMopar]

Poor old tailgate looks like its had a rough life!

 

[65 Dartman]

Poor old tailgate looks like its had a rough life!

The wagon in the junkyard that this tailgate came off of was last registered in 85 by the plates on it and was obviously well used. I’m surprised the tailgate wasn’t all rotted out down at the bottom with the window down for 35 years. Even though I have a pretty decent roof rack ready to install, I Scoffed up the roof rack on it as well which needs love as well. Maybe when it gets cooler so there’s no wasps or snakes I’ll go back and see what other parts I can harvest.

 

[65 Dartman]

It wasn't a very productive day today as wifey had other ideas of stuff we needed to get done. By the time we got back home it was getting late; however, I did get the grille support installed. The black phosphate hardware and gold anodized hood latch catch really stands out against the white paint

as does the brand new black front hood bumpers.

Passenger side:

Driver’s side:

 

[65 Dartman]

I got a hold of my sandblaster guy yesterday to see if he could come by in a day or two to get the last (hopefully) bit of blasting done - tailgate (both sides), the large tailgate access panel, the wagon-specific cover that is secured inside over the axle housing area and a Barracuda cut down floor panel I’ll use for a smooth transition between the wagon-specific panel and the rear Barracuda seat. He came by this morning and got everything blasted. Then I got everything covered in epoxy primer

Then got the tailgate panel painted in blue to match the inside side panels. Had to send wifey to the local body and paint supply for a half pint of black to paint the 2 panels which will never be seen since they’ll be covered by carpet. At least I’LL know they’re painted

Tailgate access panel in blue:

And the 2 panels that’ll never be seen in black:

 

[RustyRatRod]

I always found it strange that Ford offered the Falcon in both a 2 door sedan delivery AND 2 door station wagon and Chrysler and GM never caught on.