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Old 25-08-2014, 10:54 AM
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DaveD DaveD is offline
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Join Date: Dec 2012
Location: Melbourne
Posts: 154
Name: Dave
I’ll need to swap back to the original wheels when she’s being engineered as the Cragers are a two piece wheel & they where made illegal here in the 80’s as they can fall apart if you hit a bad enough pot hole (or some I’m told)

So this is how she’s sitting in the garage now for the last few weeks, as more bits are ordered & I find more things that really need to be fixed

The other thing that I need to do is to fit some extra mufflers to the exhaust as she has to pass a noise test at 3300 RPM & she’s miles over right now… will be fitting something that can be removed after she’s got her plates… sadly I can’t fit cut outs as they are very illegal & they can confiscate your car if your found to have them fitted… where as if I just refit a load exhaust it’s just a fine & I get 30 days to fix it.

I also need to replace the seat belts, the Chally has a set of two piece belts in the front, this means that you can wear them as a lap only belt or as a 3 pointed belt, but as the shoulder part is not retractable they have to go

Well Australia was ahead of it’s time in ’72 as they required proper drop link 3 point retractable belts in the front & 3 point retractable belts in thee rear.. I’ve found a place that makes them to suit.. so I’ll be getting a set soon & bolting them in, the fronts will go straight into the existing holes, but as the rears are lap only I’ll have to fit some mounting brackets in the rear parcel shelf & both the belts to them.

I also have to pull the dash to replace the headlight switch as the one in their now only works for the park lights, to turn the lights fully on is a 2nd switch under the dash… I was lucky to find a NOS headlight switch on the net & that’s sitting on the bench in the garage along with the NOS windscreen washer bottle & pump that I need to fit as she’s not road legal without one.

NOS windshield washer kit

I also have a new handbrake cable to fit that came with the car when I bought her of Pat...

---------- Post added at 10:54 AM ---------- Previous post was at 10:53 AM ----------

Ok, so it’s been a long time since I updated this thread now.. the good news is that I’m making good progress on the project in the Skunk Works garage, however between lots of travel for work, just general being busy at work & the fact that I keep making the list of things I want to do to the car bigger & the resultant delay that adds not only in work effort but in the weeks it can take for parts to turn up from the states.. I’m still a ways away from having this all done. On the bright side I’ve been having a ball doing the work, it’s been years since I did any sort of big project work on a car & I’d forgotten just how satisfying it can feel when you’ve replaced or repaired something on your pride & joy.. now I’ll be the first to admit that none of what I’ve done is rocket doctorary in any way shape or form but I still get a warm happy feeling at the end of a long day in the garage when I can look at something & say, I did that… it’s a great way to unwind from my normal stressful job & my incredibly understanding better half has even taken to joining me in the Skunk Works to work on the car & I don’t mean just handing me tools, she’s in there getting her hands dirty, Michelle is particularly fond of using the air tools I’ve found.

Anyway, back to the car.. so the lights are now sorted, well on the outside I still have to pull the dash apart to replace the headlight switch as it doesn’t work anymore & then whilst I’ve got the dash apart I have now also bought a new set of gauge lenses as the ones on the car are so badly scratched & foggy now that you can’t really see the gauges at all.. I’ve also ordered a new Quartz movement kit for the original Borg dash clock, these all failed in every Challenger & Cuda ever made, so I’m not going to pull the dash until I have the clock parts too & then I’ll do all 3 repairs at once.

NOS headlight switch

New Gauge cluster lenses

The next thing I figured I’d sort was the windscreen washers, as you saw in a previous post I found a NOS kit & bought that, now all I had to do was fit it into the engine bay & wire it up.. simple.. well no not really the space where it should live is now occupied by my vacuum tank for the brake booster..

A quick trail fit & it actually looked like it might just fit if I removed the vac tank & installed the washer reservoir first & then reinstalled the vac tank next to it

Once I had the vac tank off I noticed that it was rusting a lot around the central join it would need some cleaning up before I put it back in, later that day I happened to be at a car show & I spotted these for sale, so I figured you can never have enough chrome bling in the engine bay of a muscle car, so no need to tidy up the old one now.

Sorry for the pic quality or lack thereof but the camera focused on the wrong point… but you get the idea

The metal pipe that you see dangling in the air is for the charcoal canister that the car would have ran from the factory for emissions, as the canister is long gone & there is no room for a new one, I removed the pipe.. see just like Colin Chapman, I’m applying the lotus principle of adding lightness where I can…

---------- Post added at 10:54 AM ---------- Previous post was at 10:54 AM ----------

Next on the list of things to fix was to fit the new handbrake cable set that I got with the car when I bought her, now this sounded like a nice simple task, as the only parts of the old cable set-up that where still on the car was the flexi cables that connect into the rear drums & the flexi cable that runs up & into the footwell of the car & connects to the foot pedal that operates the E-Brake as the US would call it.

When I was ordering some new parts from US, I decided to get the full set of manuals for the car, so I have the Chassis, Body & Service manuals now & a complete set of the electrical diagrams.. should come in handy

The old cable had rusted itself to the car where it passes through the bodywork into the footwell, the old grommet had long perished & getting this old cable out took a lot of profanity to do the job properly

Old cable vs new

I went shopping for some new grommets so when I installed the new cable section into the footwell the cable would be protected somewhat, once I’ve finished & I’m sure the cable is not coming out again then I’ll fill the gap with some sealer to stop crap getting into the car, but until I’m 100% sure the cable doesn’t have to come out I’ll just leave her as is

Then it was onto the rears, I had to dismantle the rear drums to disconnect the cable from the handbrake adjuster in the drum

I hate undoing these stupid clips that hold on brake shoes, inevitably one always ends up shooting off into the furthest corner of the garage as the pliers slip off at some stage

Once undone I then removed the old cables, they had now set hard into an immovable shape, this did not ease the removal of them at all oddly enough


1969 Pontiac GTO - GM Weekend Toy
1972 Dodge Challenger Sixpack R/T Clone- Mopar Weekend Toy
1975 Ford XB Fairmont GS Coupe - Ford Weekend Toy
1978 Camaro - Chev Weekend Toy
4.2 Supercharged V8 RangeRover Sport - Daily driver
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