The truck guy in me instantly thinks "that will fill up with crud and rot out from the inside with that hole there" 
CK5
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The Willomet Charger
- Thread starter AgDieseler
- Start date
A desecration to Mopar nuts everywhere, this is my protouring, LS-powered, 1970 Dodge Charger; built at my shop, Willomet Motor & Fabrication.
Thanks! I’m learning a lot through this process.
That’s exactly what would happen to the factory rockers. They actually have drain holes molded into the pinch welds, which quickly clog and rot. I haven’t decided whether I’ll add drain plugs, or fill the dimple and close the rocker entirely. I’m leaning toward the latter, including using 3M pillar foam throughout.
David
Enlarge the drain holes...having a drain is a good idea. Having drains that are too small and clog easily is the bad part of that idea. It's not just "splash" that gets up in the inner areas, it's condensation.
Point taken, though I’ve cut out the original punch weld and associated drain holes. This would be for new drain holes in the .120 wall square tube inner rockers.
I didn’t think about condensation. That also has me rethinking the addition of any 3M foam, as it would greatly inhibit the flow of air. There’s a 3’ spray wand (also 3M) that lets you coat the inside of a frame rail in Rhino Liner/equivalent, which along with a passively ventilated and drained rocker may well resist rust and condensation.
David
Most foams retain some moisture as well, effectively keeping the area you want protected, damp. I have seen closed cell foam that was allegedly impervious to water used in small aluminum boats for flotation...come back to be removed two years later as the foam had waterlogged. 
That left me a little leery of foam products and water.
I ran rockers on my old Jimmy without the inner part for years. Even with nothing more than the EDM they came with, they didn't rust at all over three years of DD'ing in a super wet climate. Being wide open on the backside meant they were able to drain and dry easily. Now if I need to enclose an area I use a larger drain scenario.
That left me a little leery of foam products and water.I ran rockers on my old Jimmy without the inner part for years. Even with nothing more than the EDM they came with, they didn't rust at all over three years of DD'ing in a super wet climate. Being wide open on the backside meant they were able to drain and dry easily. Now if I need to enclose an area I use a larger drain scenario.
The Defender is back in the shop, so I only had a little bit of time on the Charger.
Everything is prepped for the new inner rocker. Once I get this side templated, I’ll be able to transfer the pattern and build the other side. I’ll lock down this passenger rocker to the frame rails before starting any cutting on the driver side.
David
Everything is prepped for the new inner rocker. Once I get this side templated, I’ll be able to transfer the pattern and build the other side. I’ll lock down this passenger rocker to the frame rails before starting any cutting on the driver side.
David
Cool stuff, David.
It's 100% apparent that I will never have enough patience to enjoy this kind of fabricating.
It's 100% apparent that I will never have enough patience to enjoy this kind of fabricating.
Thanks, Ethan.
If I had the slightest thought about driving this car within the next year, I wouldn’t have the patience, either. But, I love building it, and will honestly be a little disappointed when it’s assembled and rolling...which is a long time from now.
David
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I get what you mean Dave, I kinda enjoy the process of building too. I like having a project.
Too bad Chrysler has still not licensed complete reproduction 68-70 Dodge Charger bodies. For about $100,000 you can buy a brand new Chevy Camaro or Chevelle reproduction body, frame, engine trans, diff, interior, and own a practically brand new Chevelle or Camaro SS.
Work is looking really good.
Makes me want to restore my Nova instead of modding it.
Makes me want to restore my Nova instead of modding it.
Your project is a massive one. I'm enjoying following the house build.
For sure, and if I had that kind of coin, I'd go for new steel every time. I do not have that kind of coin.
Thanks! Either way, I don't think I've seen a stock Nova at a car show since...ever. They all seem to be tubbed or deathproofed. I'm really digging the one that Ambition Road is building right now.
David
Sh*t just got real.
David
David
#official
Just getting caught back up. I love this thread. 
Keep up the awesome work, David.
Keep up the awesome work, David.
Keep repping the brand in yooper land!
#biznass #twojobs
Thanks man. I’ve taken plenty of inspiration from your thread, so I’m glad to pay some of it back.
David
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Damn, that rocker came out really nice.
Minor update - the first inner rocker is prototyped and cleko’d.
I thought there was a single and simple taper, but it turns out Dodge built four distinct profile changes in the rocker. I think they were trying to maximize interior space. I still need to section out about 5/16” of vertical so it aligns with the external rocker profile forward of the rear quarter lead line.
Now that I have the structural envelope set, I’ll pull these off and brace internally. The existing 16ga flanges will be sandwiched by the new .120 material, so the new structure will be one with the old.
David
I thought there was a single and simple taper, but it turns out Dodge built four distinct profile changes in the rocker. I think they were trying to maximize interior space. I still need to section out about 5/16” of vertical so it aligns with the external rocker profile forward of the rear quarter lead line.
Now that I have the structural envelope set, I’ll pull these off and brace internally. The existing 16ga flanges will be sandwiched by the new .120 material, so the new structure will be one with the old.
David
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