72 Challenger Project Dodge Ball

[Dodge Ball]

I wanted to clamp in the trunk dropout before removing the wheelhouse. Enough of it is still intact so I can use it as a reference to line up the dropout.  Now when the new wheelhouse is going in I will be able to use the dropout as a reference.  At first glance it looked like a poor fit but after a little hammering and clamping, things were starting to shape up. I picked up 20 clamps from Harbor Freight for $4 each during a sale last weekend. Score!

[moparman82]

Gotta love those harbor freight sales!

[Dodge Ball]

After marking the wheelhouse , the next step is to make the cut. After cutting,  I laid the old wheelhouse over the new one and traced it (orange line). Then I measured a short distance from the orange and drew a second line (blue line). This provided an overlapping section. I then cut along the blue line,  removing the unneeded section of the new wheelhouse. Then I clamped it back in place.

[Dodge Ball]

The wheel house is not in place yet. It is actually sitting on top of the remaining part of the wheelhouse left on the car. The space between the blue and orange line is the amount of overlap between the two panels. The next step is to make a cut between the two lines through both panels to eliminate the overlap.  I stayed as close to the blue line as possible to avoid cutting where there wad no over lap. When i do the other side I will leave more of the old wheelhouse so i can have a larger overlap. After cutting you are left with a uniform line to be but welded. I inserted clamps while making the cut to help keep everything lined up. 

[Dodge Ball]

Now it's time to start spot welding along the line. At some point before welding you'll want to fit up the quarter to bake sure the wheelhouse is correctly in place and will be able to be welded to the quarter later on.

[jimynick]

Lordy that's a lot of cutting and welding. Why not just drill out the flange spot welds and put the whole thing in? You already had the upper brace drilled out and had it half fitted. Now you've got to grind all the welds, inside and out and then mud them up. Your car, your choice, but leaving the outer wheelhouse in one piece and trimming where needed would have been my choice. Anyways, it's coming together and you can't argue over that. Just my 

[Dodge Ball]

It seemed easier this way. Was it?  I don't know.  I searched for a how to and everything I found involved only replacing part of the wheelhouse.  I think the inner and outer wheelhouses are ribbon welded and I wasn't sure how separating them would go. I also didn't really want to get into removing the foreword part where it slips inside the interior.