look what I found......horrible man

[USCG Charger]

Well today I decided to take all the interior outta my car I bought last wk b/c I knew there would be a little water in the carpet. After an Hr of removing everything I made a horrifying discovery! Under my drivers side pan where the hight beam foot switch is there is a huge dent. I knew the guy hit a curb and I thought it just caused damage to the inner splash shield..... I guess I never noticed that huge mound under my feet the 3 or 4 times I actually drove it.

The dent is shaped like my wheel. It dented the fire wall and actually split the seam where the left floor pan meets the down slope behide the brake.

BTW the part that is crunched up in the pics is suppost to go straight down

Now I have a few question about this:

1) How the fock do I fix this?
2) If I buy a new Left floor pan what do I do about the huge dent proturding inward? Do I just get a mallet and knock it back into some what place, then seam it up as best I can? Or after hitting it w/a mallet and weld a new pan into place, get a sm section of sheet metel and weld it in place then seam it?
3) Do I ge a new Firewall? If so where? Pluss that seem like a PIA for sure. Or if I do get a fire wall do I just cut the section out I need the weld it?

Sorry for the rant...but it just seem like a little jopb turns into someting way outta my element.

[eldubb440]

beat it back into shape the best you can.........you will be surprised how it will want to go back the way it was....make some relief cuts if ya have to, you will have to do some welding anyway......spend a little time and sweat on it, then see what ya got

[USCG Charger]

Do you think a torch and a mallet will be easiest?

[eldubb440]

you gotta get creative......you may need a second person to "back up" the areas you are beating on.....you may even   have to cut pieces off the car, beat em straight and weld em back together...... .id throw the whole tool box at it, hammers, dollies, punches, ect

[illfish]

That's pretty bad.  The firewall even pulled off the inner fender well.  They sell an air driven planishing hammer that would work well.  Other than that, hammer and dolly.  Tough deal. . . .good luck.

[USCG Charger]

I guess I could always buy a firewall  and install it to right? Or at least cut what i need out of it...http://cgi.ebay.com/ebaymotors/67-75-DART-DUSTER-DEMON-NON-A-C-FIREWALL-COMPLETE-OEM_W0QQcmdZViewItemQQcategoryZ34204QQihZ009QQitemZ190136054520QQrdZ1QQsspagenameZWD1V

[eldubb440]

donor metal comes in real handy

[USCG Charger]

I have a door and a fender I could use... I just need a slight bend. After its in as long as its half way close I'll just put that under coating on and no one will ever know the difference.

[bOb shingler]

Do you think a torch and a mallet will be easiest?

  don't do it the thing will catch on fire and stink you out, just use a large hammer, it'll go back easy.

[USCG Charger]

So just a rubber or brass mallet should do the trick?

[Crazy68Dart]

Rubber?  Ahh no.  Get a 5-10 lbs sledge and have fun.

[USCG Charger]

Really.....wow I can't wait man.

[68_Val_Sedan]

yup a BFH and some patience and that will look like new ... like eldubb said take your time and weld it up as you go ... you will be suprised how easy it really is ...

[mischiefdart]

yup a BFH and some patience and that will look like new ... like eldubb said take your time and weld it up as you go ... you will be suprised how easy it really is ...

  You would be surprised at what you can do with a mini sledge. have a friend hold a heavy block of metal as a backer when you start getting close to the original shape. Good thing is it's not a cosmetic repair really so beat it into submission.

[signet]

this should be an easy repair.
looks like the wheel was turning when it hit the firewall,so use this info in your repair method.
also take a look at the strut rod anchor in the K-frame and also the lower control mount pivot/pin area in the K-frame.
the whole left suspension assemby was probably replaced but i doubt the changed the k-member.

whatever was hit hit hard,so look close at the front end for signs it is bent.

[mischiefdart]

whatever was hit hit hard,so look close at the front end for signs it is bent.

signet makes a good point. Does the car drive straight?

[USCG Charger]

Yes, it tracks straight....it does pull to the passenger side not sure if thats from the the hit or if its from the alignment being off.

[acpat]

of course it doesn't stop strait it has drum brakes  . beat it out/down then reweld and se where you are at. Like stated above it will want to go back where it came from. If it tracks strait and is not visible I would not worry