1970 4 door cuda?!?!

[ECS]

So you are going with the typical Assembly line fit and finish on the rest of the car ? Paint drips and all ?

There are a few drips here and there as a residual effect of the processes we used. Regarding the Seam Sealer, we have documented many vehicles that look like the examples pictured above. I will post some comparison photos to show those similarities.

The panel gaps will be as perfect as we can get make them. Since there were no Factory 4 Door Barracudas manufactured, there is no protocol to follow. If we made the gaps to the Factory standards, our efforts might be viewed as looking "home made" to the casual observer. Since the Doors will be the focal point of the car, extra scrutiny will be used to make those gaps/areas as nice as possible to showcase the craftsmanship of the custom Doors that we fabricated.

Below is an example of the gap results we achieved. No one will ever say the gaps look too nice but they would definitely consider the custom work as flawed if the slightest imperfection was visible.

 

[ECS]

Many metal cutting/alterations had to be made for the Front Header Panel and Rear Valance to fit correctly. I'll have some new photo updates showing these changes coming soon.

 

[ECS]

Boy, you sure didn't skimp on the seam sealer. Wow.

Here are a couple of comparisons. As you can see, we were not as messy as the Factory was! I'll also post one of the kick panel area as soon as I get a chance to take a picture from an original B Body vehicle. We matched the look from what we documented on those vehicles and they too were very sloppy.

 

[ECS]

After removing the Car from the Rotisserie we were able to attach the front Header Panel. We had to cut each side to keep consistent with the gaps that are seen throughout each Body Panel. The Feeler Gauge was set to a default (correct) measurement and every gap is consistent throughout the entire vehicle. Here are a few pictures showing the altering of the Header Panel and the Panel gap width throughout the Car.

 

[Bill]

I didn't know they used feeler guages to put these cars together back in 1970?? (LOL)
Very interesting and awesome project!!

 

[ECS]

I didn't know they used feeler guages to put these cars together back in 1970??

There were Engineering specifications that provided the appropriate gap measurements for the Body Panels of Factory Vehicles. You can reference those measurements in the Chrysler Assembly Manuals. The feeler gauge allowed us to monitor those specs because we built the entire vehicle from scratch! We never had the leisure of starting with an existing car that had been assembled and those "gap specifications" already factored into the build of the vehicle.


It makes one wonder what method we should have used to determine the proper gaps for a 4 Door Barracuda that was never manufactured? Come to think of it, we've probably employed many procedures never used by the Assembly Line in order to fabricate a vehicle that was never built by the Factory! (lol) Oh well.........

 

[aussiemark]

Those gaps are awesome, was the header panel too long or short?, was it OEM or after market if so what brand?

 

[ECS]

Those gaps are awesome, was the header panel too long or short?, was it OEM or after market if so what brand?

We used as many "reproduction" Body Panels as possible. Some were AMD and some were made by other Companies. The Hood was not offered by AMD so we had to use a different brand. (I can't recall who made the hood.)

I feel really bad for those who have to use reproduction Body Panels as their main source for Body parts. It seems like we had to alter EVERY Panel to match the original versions. The Fenders had to be re-worked to get the correct shape. The Hood, Trunk, Valances, Rear Tail Panel, etc..... ALL had major re-construction to make them fit & appear "original". To look at the Car now, you would never know that the work was done. Thanks to MANY HUNDREDS of hours of work, the Body Panels all have the appearance of Factory parts.

 

[C O D Y]

I just love love seeing photos of the work you've done! Nice job!!!!!!

 

[BH41H0B]

Now that the weather is breaking I plan to take a trek out to see this car. I will definitely take a camera and document the findings.

 

[ECS]

I just love love seeing photos of the work you've done! Nice job!!!!!!

Here are the Fender Tags we decided to put on the Car.

 

[ECS]

We've had many questions about how we were going to re-work the interior to alter some of the areas that required reconstruction and/or customization. One of the main areas that had to be altered was between the Rear Seat and the Arm Seat area. Since 'stock" 1970 Barracuda rear arm rest pieces could not be used, we had hard foam blocks made to to sculpt our custom panels. They are actually solid sections of foam that had to be carved & shaped to represent the authentic look of a Factory component.

Here are a few photos showing the progression of the Interior conversions and comparison photos between Factory Barracuda plastic panels and what we shaped. After they are completely finished, we will have them wrapped in black Vinyl Material that matches the Interior of the Car. Also included are a few photos that show the overall Body proportions of the 4 Door Barracuda Project.

 

[aussiemark]

How will you make the door trim panels?

 

[ECS]

How will you make the door trim panels?

Here are a few more exterior pictures. The Custom Interior Door Panels will be posted next.

 

[ECS]

Below are a few photos of the Custom Interior Filler pieces that sit beside the Rear Seat and the top corner of the Package Tray Shelf. There are still a few tweaks that need to be made before the final fit is complete and the dense foam is ready to be covered with vinyl material. The small foam piece will be glued to the larger section to make a one piece monolithic component. I included the 3 shaping stages that illustrate the transition to form the small foam pieces that sit on the Package Tray Shelf.

Also included are some shots of the custom gaps between the top of the Rear Doors, the Custom Quarter Panels and the Trunk Deck Lid. The gaps at the top of the Rear Doors were completely fabricated to that represent that meandering shape. Both the front & rear Door Skins were custom made and never existed until Steve cut their patterns, fabricated the attaching folded edges and the formed the correct curvature to emulate the stock Barracuda Body lines.

 

[ECS]

Here's a few more of the underside while the Shell is sitting on the 4 roller stands. I'll have some more that show all the different over-sprays when everything is complete. These just show the Dip Coat, Red Oxide and Gray Primer.

 

[ECS]

Here are a few progression pictures of the custom Light Boxes that will sit at the base of the (hard) Foam Panel Filler sections that were fabricated. We will use a Convertible Light Harness setup that will allow the Rear Floor area to be lit up when the Rear Doors are opened. The Boxes were cut from the left over (front Door Skin) Sheet Metal that was used to fabricate the back section of the Rear Door Skins. We purchase 2 Cuda Door Skins in order to get the additional Door Handle opening required for the custom Rear Door. The front section was basically scrap after the panel had been cut apart.

Steve was able to cut the metal and bend it by hand to get the appropriate Box size for fit & finish. He incorporated louvered openings that will allow the illumination to have a soft diffused look when the light is activated by opening the rear Doors. I put the formed boxes back into the piece of metal they were cut from and you can see those examples in the third picture. They will be painted a Textured, Black color when they are ready for installation. The Interior Door Panels are being constructed and should be finished shortly.

Inside/Backside of the Light Box

Finished - Primed Light Box

 

[burntorange70]

Lot of trick little details and custom made coolness going on. Was not so sure about this more door thing at first but the more I see the more I am digging it.

 

[moparleo]

Just thinking out loud, A four door car is more of a luxury car than a 2 door sports car. Have you given any thought to a Challenger SE type of rear window plug ?

 

[ECS]

Have you given any thought to a Challenger SE type of rear window plug ?

No we have not. To do so would require completely redesigning and undoing the roof structure and "stock" Barracuda glass opening that we spent months of effort designing and custom shaping into its current form.