Project Charger. Larry Lyles

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Project Charger - Larry Lyles

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      Karla Austin, Business Operations Manager

      Jen Dorsey, Associate Editor

      Michelle Martinez, Assistant Editor

      Rebekah Bryant, Editorial Assistant

      Erin Kuechenmeister, Production Editor

      Ruth Strother, Editor-At-Large

      Nick Clemente, Special Consultant

      Vicky Vaughn, Book Designer

      Copyright© 2004 by Larry Lyles

      All rights reserved. No part of this book may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of I-5 Press™, except for the inclusion of brief quotations in an acknowledged review.

      Library of Congress Cataloging-in-Publication Data

      Lyles, Larry.

      Project Charger : the step-by-step restoration of a popular vintage car / Larry Lyles.

      p. cm.

      ISBN 1-931993-22-X (softcover : alk. paper)

      eISBN 978-1-62008-015-3

      1. Dodge Charger automobile—Conservation and restoration. I. Title.

      TL215.D64L95 2004

      629.28’722—dc22

      2003022778

      I-5 Press™

      A Division of I-5 Publishing, LLC™

      3 Burroughs

      Irvine, California 92618

      Printed and bound in Singapore

      10 9 8 7 6 5 4 3 2 1

       Table of Contents

       Acknowledgments

       Introduction

       1 Starting the Project

       2 Teardown Begins

       3 Glass Removal

       4 Exterior Teardown

       5 Moldings and Body Lines

       6 Removing the Engine

       7 Cowl Teardown

       8 Reassembly Begins

       9 Restoring the Trunk Floor Plan

       10 Sheet Metal Repair

       11 Refinishing the Underbody

       12 Priming and Blocking

       13 Refinishing the Exterior and Interior

       14 Refinishing the Components

       15 Powder Coating

       16 Machine Work

       17 Trim Work Begins

       18 Window Tint and Door Glasses

       19 Suspension Installation

       20 Drive Line Installation

       21 Front Sheet Metal

       22 Bumpers, Decals, and Stripes

       23 Interior Trim

       24 A Look Back

       Resources and Restoration Costs

       Acknowledgments

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       I would like to thank the many people who helped bring this project to life. To my wife, Pat, who understands the feeling of power and freedom a restored muscle car can bring, I say, “Thanks, here are the keys. Have fun.” To Bryan, who worked harder on this project than I could have ever expected, I say, “Thanks, here are the keys. Take it for a ride then get back to work.” To Ted Kade, editor of Auto Restorer magazine, I say, “Thanks, my friend. Here are the keys. Don’t come back until the fuel tank runs dry.” To everyone else who contributed so much toward the completion of this project I can only say, “Thanks. Wish you could be here to enjoy this car as much as we do.”

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       Introduction

      I originally wrote a 24-article series for Auto Restorer magazine. My intent was to take readers through a complete ground up restoration of a classic muscle car while offering real world information on how to accomplish such a restoration. This book is a compilation of those articles.

      As a seasoned veteran of automotive

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