Gary Kuster's "Plodge" Adventures



Works in progress. Or, whose progress has been completed!
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Faulkner
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Gary Kuster's "Plodge" Adventures

Post by Faulkner »

Here you'll find the detail on how Gary built his '59 "Plodge" Mayfair, "Finnegan". Visit it in The Showcase!

Trying to decode my car and not having much luck probably because it's a Canadian car?

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I want to be sure it's a 313 poly before I order any parts!

[The Canadian data plate in the first pic is inscrutable to me, Gary - but the VIN plate on the door post shares the format with the US. The "M" indicates the 1959 model year; the 8 indicates the car line (not a US number - probably indicates CN Dodge); the 5 indicates the model (5 is for Mayfair, the Belvedere equivalent), and the 9 indicates that it was built in Windsor, CN. The rest of the number is where your car fell in production, starting with 100001. Yours was the 2,252nd off the line in Windsor.

I don't know if Plodges were ever built with a 361 equivalent - another V8 option for Plymouth - but your engine is definitely a Poly as I'm sure you now know, based on the location of the distributor in the rear and the scalloped valve covers. -Dan]
"If it's new, Plymouth's got it!"
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Some paint remediation

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Arms are about to fall off from all the compounding, sanding and waxing...
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...but there seems to be a Plodge under the dirt and oxidation.
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The roof is still the original paint and after removing the tree sap with a razor blade and compounding, it came back pretty good.
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The hood, though, is another story
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I cleaned and sanded the hood. I removed a layer of dirt and oxidation.
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I cleaned and sanded the hood. I removed a layer of dirt and oxidation. Looks a little better, but lots of missing paint. You can't make a silk purse out of a Sow's ear, but you can try.
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A little more progress on the front end. I'm just cleaning it up a bit for fun.
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Eventually, it will have to be stripped properly for paint.
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Hood is in primer!
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The trunk lid will soon get similar treatment - along with the trunk itself
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"If it's new, Plymouth's got it!"
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Poly Problems

Post by Faulkner »

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Still waiting for my Shop manuals and Canadian supplement to arrive, but decided to chase after the rough idle. Did a compression test and found the shake. Pass side rear cyl. inop. I had heard the valves were adjustable, so I was hoping for a tight valve. Took off the valve cover and massive clearance on the intake valve Missing some push rod as the stump is still in the head.
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I did manage to get the upper portion of the pushrod out by moving the rocker out of the way. It looks like it was bent before it let go. Probably some past owner over-revved the engine.
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I fished for the lower end of the pushrod for over 2 hours with a telescopic magnet. When that didn't work, the intake had to come off. Did all the lifters while I was in there. Engine looked like new inside.
"If it's new, Plymouth's got it!"
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Gotta Have Tunes

Post by Faulkner »

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Purchased what I hope is the original radio for my Dodge Mayfair (Plodge).
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It has no Chryco/Mopar etc. stickers or numbers. Just says "Deluxe" on the dial.
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Mismatched knobs as well, hope at least one is correct.
"If it's new, Plymouth's got it!"
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What Lurks Beneath

Post by Faulkner »

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When I bought the car, it had black rubber flooring.
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But I could see something red sticking out where it was torn. I pulled up the rubber flooring and the red carpet was underneath.
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Sombody in the past, had to have unbolted the drivers seat, installed the correct Plodge rubber matt over the carpet and put the seat back in! Perhaps to "save" the carpet, like they did with lampshades and sofas back in the day?
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The rubber keeping the carpet damp did a great job rusting out the floor.
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As they say in Nowfoundland (discussing a retrofit on a ship) "she's rusted from appetite to arsehole" so was my floor.
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Couldn't sleep, wandered into the garage and saw I left my trouble light on. Even looks good in the dark!
"If it's new, Plymouth's got it!"
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Face Lift

Post by Faulkner »

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What a great day to work on the Dodge! Removed the cover,put the battery back in,dribble a little gas into the carb and varoom! Drove it into the garage and proceeded to give it a face lift...
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reinstalling the re-chromed bumper
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Took most of the day, but Finnegan's front is done! I went with a Black mesh grill to highlight the chrome. Easily undone if the next person doesn't like it.
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Can't tell me George Barris didn't borrow the "Look" for the Batmobile from this '59 Dodge
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Interior is pretty decent on this one. headliner and seats redone. Not particularly well, but redone. No Mice ever...
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working dome light!
"If it's new, Plymouth's got it!"
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All's Weld That Ends Weld

Post by Faulkner »

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Getting ready to replace my inner and outer rockers and sections of the floor on my 1959 Dodge Mayfair (Plodge) I have a Lincoln electric welder and a torch set. I'm far better at brazing/welding. Is any one way better than another? Have done a lot of metal work on other cars all with welding/brazing. Only used electric to tack exhaust when I had my shop. Floor panels should arrive today.
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I started on the floor, inner and outer rockers. Worst rust was Lf. rear behind drivers seat. Cut everything out and replaced the aft section of the inner rocker. Cut out lf. rear floor and replaced it. Used a combination of mig and old fashioned brazing. Did it on the floor rather than up on the hoist as I could see the doors misaligning slightly when on the hoist.
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I usually pick things up pretty quick, but I suck at Mig welding. Outer rocker is only a test fit. It goes on last. Have to do both inner rockers first.


The entire floor pan,(6 sections) both inner and outer rockers are all available from Classic to Current. I only have to fabricate some of the rusted cross braces.

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Finished the drivers side floor!
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The gas pedal assembly goes through a hole in the floor. I see no trace of a rubber boot or the like. I have the 4 vol. set of the manuals for the Canadian version, but no illustration of the pedal. What goes there? Edit: Thanks for all the help, got a part number!
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"If it's new, Plymouth's got it!"
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Getting a Dog Leg Up

Post by Faulkner »

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Spent the morning Fabbing up and welding in the rusted Lf. dog leg. Not my favorite repair, but glad the metalwork is done.
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New rocker fits well and the gaps under the door are good. Lf. rear Inner fender needed some love as well.
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Skim of bondo and test fit of the chrome trim. That's enough for today. It will stay in white primer until spring.
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Not ready for paint by a long shot, but a good 10 footer!
"If it's new, Plymouth's got it!"
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Bringing Up The Rear

Post by Faulkner »

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Working on the rear of the body on my '59 Plodge - the rear window seal. I cleaned it best I could and dug out anything loose and added more sealer. The is a small water leak in the trunk at the corners,not the middle. Stays indoors until I deal with it. I would prefer to pull the rear glass and reseal one day.
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Wow! removing the trunk seal from the channel is brutal! To much stuff bouncing off my face, will have to invest in a face shield! Safety glasses aren't cutting it.


This is the part where I tell myself "Just finish the damn thing! Nobody's gonna see that on a white car!" Stalling for time before finishing the pass floor and rockers
"If it's new, Plymouth's got it!"
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Take No Passengers

Post by Faulkner »

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As good as the drivers side quarter panel is, the pass side is pretty bad. I need repair pieces for the area ahead of the rt. rear wheel, (behind the little chrome plate)...
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...the lower part behind the wheel and especially the top of the wheel arch. Is anyone fabbing these parts?
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Hmmm...
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Giving the trunk lid similar treatment as the hood
"If it's new, Plymouth's got it!"
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Finishing Up Driver's Side

Post by Faulkner »

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Bodywork and painting continues on the '59 Dodge
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Drivers side is done except paint correction and polish. Time to spin it around and do the pass side.
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"If it's new, Plymouth's got it!"
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Taillights

Post by Faulkner »

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I'm getting the taillight assy's from the '59 Plodge ready to go out for chroming and I can't seem to remove the bulb sockets.
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They look pressed in place. Do I have to break them out and replace them?


[The answer is yes! They're pressed in, and must be broken out.]
"If it's new, Plymouth's got it!"
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Trunk Part I

Post by Faulkner »

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Working on the back of the Plodge (The Plymouth end) and i noticed a row of holes that wouldn't be visible with the bumper in place...
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Was there a filler strip at some point between the bumper and the back of the car?


[Yup! They are neoprene, and Quirey Quality Design (who bought out Gary Goers) has 'em, along with the clips that hold them into place. -Dan]

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The Plodge got some lovin' this week! Cleaning the rust up around the trunk seal and cleaning and fixing the pin holes in the trunk pan and sealing with epoxy and paint!
"If it's new, Plymouth's got it!"
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Another Task Weld Done

Post by Faulkner »

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Spent the day cutting out the rust at the rt. rear corner below the C pillar. Very rusty part of the car. Rebuilt the cross member below.
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Replaced the rotted metal inside the car and will reinstall the body to frame mount tomorrow. Rear section of inner rocker in place as well. Hopefully, I'll have the rear pass pan installed by tomorrow.
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Got the pass rear floor done today on the '59 Plodge.
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Mocked up the rocker for fun.
"If it's new, Plymouth's got it!"
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Junk in the Trunk

Post by Faulkner »

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Done with the '59 Plodge bum. 6 week wait for the tail lights to come back from the chrome guys.
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The A body GM. trunk seal doesn't work. I will have to find a correct seal (which I subsequently did - again from Quirey!)
"If it's new, Plymouth's got it!"
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