After carefully pondering what to do for my rear window plug, I decided to make my own from 16 gauge cold-rolled steel, useing Ted Janak's fiberglass plug as a pattern. I decided to make it in sections, one at a time, since fabricating the whole thing in one piece would be a real bitch. I've got the first section, what I'll call the "Dutchman" panel about 70% done...here's a few pics:
Here's a few more:
Impressive...
I HOPE AFTER ALL THAT WORK YOUR NOT GOING TO USE A LEXAN BACKLITE. WHAT ARE YOUR OPTIONS FOR MOULDINGS
Quote from: hotrod98 on March 05, 2006, 11:10:23 PM
Impressive...
:iagree: :bow:
That really does look nice!!
Quote from: daytonalo on March 05, 2006, 11:11:33 PM
I HOPE AFTER ALL THAT WORK YOUR NOT GOING TO USE A LEXAN BACKLITE. WHAT ARE YOUR OPTIONS FOR MOULDINGS
I've got the new reproduction glass rear window from Iowa Glass, and I'll be making the trim from pieces of the original charger rear window trim...
Very freaking amazing!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
How are you going to do the lip to hold the window. Again WOW
Hats off.
Quote from: Daytona Guy on March 05, 2006, 11:51:09 PM
Very freaking amazing!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
How are you going to do the lip to hold the window. Again WOW
Hats off.
Thanks, Dane! :wave: Coming from a guy that has already Cloned nine of these things, that's a terrific compliment! :-[
As far as the glass channel goes, I'll do just like I've done on the trunk drip channel--Form a strip of metal into a 90 degree angle on the press brake at work, then bring it home and form the compound curves by hand :icon_smile_big:
HOW MUCH WAS THE BACKLITE FROM IOWA GLASS. LARRY
You are a true craftsman...Nice!
Excellent work. I think it will look great, it already does. One question though, I haven't seen a lot of these clone rear windows in process but don't you guys normally remove the inner portion of the sail panels? Seems like it would make things easier when it comes to doing the interior.
Quote from: daytonalo on March 06, 2006, 03:04:25 AM
HOW MUCH WAS THE BACKLITE FROM IOWA GLASS. LARRY
Larry, The backlight was $675.
Quote from: wetfeetmi on March 06, 2006, 06:37:08 AM
You are a true craftsman...Nice!
Thanks, Feet! :wave:
Quote from: bull on March 06, 2006, 06:50:25 AM
Excellent work. I think it will look great, it already does. One question though, I haven't seen a lot of these clone rear windows in process but don't you guys normally remove the inner portion of the sail panels? Seems like it would make things easier when it comes to doing the interior.
Thanks, Bull. :wave: There is really no need to cut out the sail panels, They really aren't in the way and they make up much of the structural rigidity of the car. I did make a small notch where the sail panels meet the rear deck on the inside for clearance, but I could have made the notch on the plug instead if I had wanted to. I don't see any problems with the interior as long as I install the headliner mounting "teeth" before I weld the plug in.
Quote from: bull on March 06, 2006, 06:50:25 AM
Excellent work. I think it will look great, it already does. One question though, I haven't seen a lot of these clone rear windows in process but don't you guys normally remove the inner portion of the sail panels? Seems like it would make things easier when it comes to doing the interior.
Bull,
If you study an original daytona, it's surprising as to how little they actually altered. They left the inner sail panels, the back glass channel and even the dutchman panel is still there under the plug. They simply notched the original trunk opening where the new plug was welded in. Even the original trunk hinge mounts are used. The first time I saw one I was very surprised. It made me realize that converting a charger into a daytona was not rocket scientry. Here's a couple of pics that some one posted a while back showing the underside of the dutchman panel area.
larry
hotrod98
wow, that looks great!
Amazing...
I haven't had much time to work on my Daytona clone lately, but I did manage to get around to finishing the lower section (aka the "Dutchman" panel) of my homemade steel rear window plug yesterday... here's a few pics:
nice work
A+ JOB , MY HATS OFF TO YOU , I'VE BEEN TOLD THAT I WAS PRETTY GOOD, BUT YOU MAKE ME LOOK LIKE ONE OF JERRY'S KIDS ! LARRY
Thanks, Larry! I just wish I had more time to work on it...
Quote from: daytonalo on April 02, 2006, 04:06:03 PM
YOU MAKE ME LOOK LIKE ONE OF JERRY'S KIDS ! LARRY
:smilielol:
JUST A THOUGHT AS I LOOK AT MY ORIG WINDOW FROM MY CHARGER , ITS NOT THAT MUCH SMALLER THAN THE DAYTONA . I USED A VEGA PLUG BUT MAYBE NEXT TIME I MAKE A PLUG IN WHICH I CAN USE MY ORIG GLASS AND THE BIG THING HERE IS NO MOLDING PROBLEM ! LARRY
Back last year when I showed my wife the vega plug, she said: "why don't you just cut around the orginal channel, tilt it up, weld it in place and use the stock glass and moldings."
Larry...don't encourage her.
HOW MUCH SMALLER IS A STOCK BACKLITE WHEN COMPARED TO DAYTONA BACKLITE ? AS YOU KNOW I USED A VEGA BACK LITE LARRY
Quote from: daytonalo on April 02, 2006, 08:08:25 PM
JUST A THOUGHT AS I LOOK AT MY ORIG WINDOW FROM MY CHARGER , ITS NOT THAT MUCH SMALLER THAN THE DAYTONA . I USED A VEGA PLUG BUT MAYBE NEXT TIME I MAKE A PLUG IN WHICH I CAN USE MY ORIG GLASS AND THE BIG THING HERE IS NO MOLDING PROBLEM ! LARRY
Larry,(Daytonalo) and Larry(Hotrod98) I'm way ahead of you guys on this one. The first thing I did when I started on this whole clone thing was prop the original charger glass into the sail panel area to see if this idea would work, thought it would save alot of B.S, by just repositioning the rear glass/channel and building a plug around it...Well, it sounds like a good idea, BUT-The curvature of the glass was WAY off - too flat across the bottom if I remember correctly...so no dice, and yes I even tried it with the glass upside down :eyes:
Thank god I didn't sell the vega plug. ;D
HOW MUCH WARPAGE WAS THERE ?
thats some awesome metal working skill you have got there :scope: awesome job :2thumbs:
That is some fine craftsmanship. So when are you going into production?! :icon_smile_question: That is the only part that I did not get from Janek when I was buying it.
Quote from: Howie on April 03, 2006, 02:07:31 PM
So when are you going into production?! :icon_smile_question:
Hmmmmm... :scratchchin:
Nice work the plug looks great! I was watching American Chopper the other day,and they were making parts on the water jet machine,and it got me thinking,if someone scanned the rear window moldings,could that machine make them up maybe using billet,that could be polished! Just a thought!
:popcrn:So how is that rear plug coming along? Inquiring minds want to know! :icon_smile_approve:
Quote from: Howie on April 20, 2006, 02:07:40 PM
:popcrn:So how is that rear plug coming along? Inquiring minds want to know! :icon_smile_approve:
I haven't had much time to work on it lately, damned boss expects me to go to work every day :flame:
There might be some progress worthy of taking a picture of this weekend...stay tuned ;)
Very impressive set of hands you got, not to mention the know how. Who ever said it couldn't be done hasn't met you. :yesnod:
I would love to be able to fab something like that up. :o
Well, I finally got around to finishing my Homemade rear window plug yesterday.
There are still a couple small details that I need to take car of, like mounting the bracket that holds the switch for the trunk light, and I need to remove the plug from the car a final time so I can flip it over on the bench and fabricate the mountings for the headliner "teeth". Then before I weld it on for good I need to test fit the glass and fabricate the stainless trim....but the really hard part, the major fabrication work is done :cheers:
Feast your eyes :icon_smile_cool:
The first pic is the header panel fabricated and ready to be fitted to the car.
The second pic is the header panel in place on the car.
The third pic is one of the side rails coming together.
The last pic is the finished plug temporarily tack welded in place...
wow, that looks great. :thumbs:
Quote from: 472 RT/SE on April 23, 2006, 10:49:04 PM
Very impressive set of hands you got, not to mention the know how. Who ever said it couldn't be done hasn't met you. :yesnod:
I would love to be able to fab something like that up. :o
Easier just to quote my last response.
Hey RT/SE, don't you worry about flash rust on all that bare steel? Sometimes I will return to the shop the following day after stripping steel bare, and I will see and feel rust forming overnite! I have been in the habit of spraying steel with zinc or etching primer out of a spray can just for this very reason. Maybe it is the humidity around here in MI. Rick
Quote from: wetfeetmi on May 29, 2006, 07:33:10 AM
Hey RT/SE, don't you worry about flash rust on all that bare steel? Sometimes I will return to the shop the following day after stripping steel bare, and I will see and feel rust forming overnite! I have been in the habit of spraying steel with zinc or etching primer out of a spray can just for this very reason. Maybe it is the humidity around here in MI. Rick
Flash rust hasn't been a big problem for me. That's not to say I haven't had a few incidents :-[ (Nothing a few swipes of the ol' scocthbrite won't take care of.) I run a dehumidifier in my garage year round, and try to keep the temperature relatively constant. So far I've been able to manage it pretty well even though it does get very humid here in southern Illinois...
:scope: awesome work :2thumbs:
Thanks for the compliments guys, I'm very proud of how the plug turned out.
For those of you who have PM'ed me asking me to make a plug for you, (several of you have ;) ) the answer is no, not right now, anyway. I have to concentrate my efforts on getting my Daytona Clone done.
:drive:
Wow, your talent amazes me! That is way cool man.
Quote from: Daytona R/T SE on May 30, 2006, 09:46:11 PM
Thanks for the compliments guys, I'm very proud of how the plug turned out.
For those of you who have PM'ed me asking me to make a plug for you, (several of you have ;) ) the answer is no, not right now, anyway. I have to concentrate my efforts on getting my Daytona Clone done.
:drive:
I bet you got several offers. THAT IS GREAT WORK. You would definately be able to sell those, however, time to make them is another factor.
GOOD WORK, KEEP THE PICTURES posted as you go.
Tom
If you saw the blown magnumforce daytona driving down the highway on this week's episode of Wrecks To Riches, I'll bet that lit a fire under you. I know it gave me a chubby. :icon_smile_big:
hell yeah dude saw that episode and my jaw dropped when i saw that blown 'tona rippin down the hwy, good thing i taped it ;D-MATT
Quote from: Daytona R/T SE on April 03, 2006, 05:24:38 PM
Quote from: Howie on April 03, 2006, 02:07:31 PM
So when are you going into production?! :icon_smile_question:
Hmmmmm... :scratchchin:
I'm in for one if you do!
So now what is the fate of the fiberglass plug? In quiring minds want to know.
Quote from: Howie on June 02, 2006, 02:04:33 PM
So now what is the fate of the fiberglass plug? In quiring minds want to know.
I'm just going to hang onto it, I've got another project in mind for later on...the fiberglass plug just might come in handy.... :scratchchin:
Just thought I'd add a few more recent pics:
In the first pic on the left is the Fiberglass plug "Made In Texas" that I used as a pattern to make my own plug, On the right is my finished home made steel plug "Made in Illinois"
The second pic shows the plug tack welded in place with the reproduction glass from Iowa Glass being test fitted.
The third pic shows the plug FINALLY welded in place on the car.
The last pic shows the car as of yesterday with the wing and trunklid installed...
And a shot of the trunk ;D ...
wow! looks great. Rene
wow 2 more awesome work(Daytona R/T SE ) :scope: :2thumbs:
Your car's coming together nice. Can't wait to see the finished product.
Now that I have my hemi chal convert finished, I'm going to convert bigblocksam's and Howie's trunk lids and start installing Howie's vega plug. Then maybe I can get started on one of my wing car projects.
I just wish that my daytona clone was as far along as yours. ;D
Yeah, it's coming along, but I wish I could get it done quicker! The goal is to get it all ready to go to my Buddy Ronnie's shop for the final body work and paint sometime this fall...I've still got a L-O-N-G way to go before it's ready for that....But I'M WORKING ON IT!!! :yesnod:
QuoteBut I'M WORKING ON IT!!!
you certainly are.it's getting there. :yesnod:
That is some very impressive work. Keep it up.
I know nothing about metal work, welding and or fabrication, but I must say that they quality of the work you've done looks spot - congrats, it's actually very inspiring.
:iagree: Very cool! :thumbs:
I also like the naked Charger look, something about a bare steel car that just looks too cool. :yesnod:
WOW, I cannot say it enough, freaking great work man!!!!
personally i think that flush back window looks way better then the tunneled one usually on the 68-70 chargers-MATT
:o HOLY SMOKES!! i'm gonna increase my 401k contribution to 20% next year so i can retire 10 years earlier and finally get to doing my dream job which is exactly what you are doing....
Quote from: PocketThunder on August 18, 2006, 10:27:58 AM
:o HOLY SMOKES!! i'm gonna increase my 401k contribution to 20% next year so i can retire 10 years earlier and finally get to doing my dream job which is exactly what you are doing....
C'mon down Pocket! I'll teach you everything I know! ;)
Quick Question, when the decklid is closed , I made my own lower jamb area and need to know the distance between the area where the weatherstrip sits and the decklid cap when the decklid is closed. It seems that my gap is excessive , probably because of the compound curve . If you could look through the tail light opening and let me know , it would be greatly appreciated ,Thank you ,Larry
Quote from: daytonalo on August 19, 2006, 10:00:58 AM
Quick Question, when the decklid is closed , I made my own lower jamb area and need to know the distance between the area where the weatherstrip sits and the decklid cap when the decklid is closed. It seems that my gap is excessive , probably because of the compound curve . If you could look through the tail light opening and let me know , it would be greatly appreciated ,Thank you ,Larry
Larry, I just went out and checked the clearance. For lack of a better way to measure, I rolled up several balls of modeling clay, positioned them along the rail where the gasket should be and then closed and latched the trunklid. The thinnest piece of clay after the closing was 1/4 of an inch and the thickest was 5/16 of an inch-so my clearance is 1/4"- 5/16" I don't know if that's right, but that's the way mine turned out...might have to do this test on one of my "regular" chargers...
QuoteLarry, I just went out and checked the clearance. For lack of a better way to measure, I rolled up several balls of modeling clay, positioned them along the rail where the gasket should be and then closed and latched the trunklid. The thinnest piece of clay after the closing was 1/4 of an inch and the thickest was 5/16 of an inch-so my clearance is 1/4"- 5/16" I don't know if that's right, but that's the way mine turned out...might have to do this test on one of my "regular" chargers...
outstanding my friend, that's how to help a charger bud.
Quote from: BigBlockSam on August 19, 2006, 11:31:49 PM
QuoteLarry, I just went out and checked the clearance. For lack of a better way to measure, I rolled up several balls of modeling clay, positioned them along the rail where the gasket should be and then closed and latched the trunklid. The thinnest piece of clay after the closing was 1/4 of an inch and the thickest was 5/16 of an inch-so my clearance is 1/4"- 5/16" I don't know if that's right, but that's the way mine turned out...might have to do this test on one of my "regular" chargers...
outstanding my friend, that's how to help a charger bud.
Glad to help :thumbs:
Thank you , my gap is a little on the fat side , I will have to tweet it a little . Outstanding craftmenship ! One question , what are you going to use for moulding's ? Stock charger , and tig in an extra section ? Forgive me if this has been covered previously .
Larry
Quote from: daytonalo on August 21, 2006, 10:10:56 AM
Thank you , my gap is a little on the fat side , I will have to tweet it a little . Outstanding craftmenship ! One question , what are you going to use for moulding's ? Stock charger , and tig in an extra section ? Forgive me if this has been covered previously .
Larry
Yep, I'm going to piece together some trim from stock Charger trim. Just haven't gotten that far yet....
what colour is your daytona r/t se clone gonna be? b5 like your pic?-MATT
Quote from: B5 BLUE CHARGER PUNK on August 24, 2006, 03:43:42 PM
what colour is your daytona r/t se clone gonna be? b5 like your pic?-MATT
The picture in my posts is the planned color scheme. 'Cept my car will have the white interior and retain all of it's R/T SE stuff, hence the username "Daytona R/T SE" ;D
I'm glad that I'm not the only one using a real R/T SE car to build a Daytona clone. My car's a triple black car and I would like to keep it black/black but it gets so stinking hot here in the south. You can fry eggs on the hood of a black car down here in July and August. My second choice is red with a white wing. I like the blue that you've chosen. I'm assuming it's B5 blue. You don't see many blue daytonas.
Quote from: hotrod98 on August 24, 2006, 09:38:47 PM
I'm glad that I'm not the only one using a real R/T SE car to build a Daytona clone. I'm assuming it's B5 blue. You don't see many blue daytonas.
Larry, Here's what my car started out as soooooo long ago, an F8 Green :icon_smile_dead: With Green interior :icon_smile_dead: Black top,white stripe 69 R/T SE. It took a lot of time and money to get that ugly F8 green off of my car, but at this point I'm pretty sure I got it all ;)
The finished product will be B-5, White wing, White interior, with all the SE woodgrain, etc. and yes, it will retain it's R/T emblem on the tailpanel and the SE emblems on the sail panels... The Number Nazis are going to hate this one ;D
cool looking car man. i see your vision. man!, that looks great. :2thumbs:
Quote from: BigBlockSam on August 24, 2006, 11:06:42 PM
cool looking car man. i see your vision. man!, that looks great. :2thumbs:
Thanks,Sam! That vision is occasionally blurred by grinding dust and weld flash :scope:
thats the only way to get it done. :musik010:
What you've done so far is truely remarkable. Keep up the awesome work, I can't wait to see her when she's done. ;D
Quote from: Bandit4142 on September 17, 2006, 03:52:26 PM
What you've done so far is truely remarkable. Keep up the awesome work, I can't wait to see her when she's done. ;D
Thanks, Bandit ! I can't wait to see it done,either! ;)
you do some awesome metal work dude, :bow: sounds & looks like a good project to (daytona ) that 69 R/T SE . would like to see pictures of its progress
Nice job! I want to do a clone a Daytona someday soon. I assume the trunk lid is shorter. How did you alter the trunk lid? Did you just cut it to the right size and reform the structural underside to fit?
Thanks,
That's ok. I found out how it's done (shorten trunk lid) at this thread. http://www.dodgecharger.com/forum/index.php/topic,18266.0.html
To do it right, it requires a steel closeout panel that is quickly becoming hard to find. If you would like to have one altered, I charge $550 to alter your trunk lid and that includes the steel closeout panel and the hinge mounts. There are others converting these with the fiberglass closeout panels, but I can't see where they would stay together. We're working on the hinges now and they'll run $250 a pair if purchased at the same time that the trunk is altered. We're working on other parts as well. It's just taking a lot longer than we had planned.