Cap MIRROR CONTROL: I found a remote mirror set with the cap MIRROR CONTROL, didn’t see before and missing in my car (01). When arrived it showed scratched and too wasted, couldn't repair better (02). I had to remake another cap.

First model in 3D-RealView with engraved letters (03) (04), then 3D-Print in black, fill the letters in white (05) and hook up on the nut (06).

Now the heavy chrome has reduced somewhat, the aspect more appealing (07).  - SERGE -   ;)

N.B. The cap was printed in FDM-Technology. Will redo in SLA-Technology for much higher accuracy of the engraved letters. When done I will replace and present here.

(01 Remote Mirror Set.jpg)

(02 Cap MIRROR CONTROL OR.jpg)

(03 Cap MIRROR CONTROL CAD.jpg)

(04 Version Smaller Center CAD.jpg)

(05 Painting Letters on 3D-Print .jpg)

(06 Cap Hooked up.jpg)

(07 Final Front View.jpg)

01 Remote Mirror Set.jpg (102KB - 52 downloads)

02 Cap MIRROR CONTROL OR.jpg (57KB - 50 downloads)

03 Cap MIRROR CONTROL CAD.jpg (95KB - 57 downloads)

04 Version Smaller Center CAD.jpg (69KB - 48 downloads)

05 Painting Letters on 3D-Print .jpg (90KB - 48 downloads)

06 Cap Hooked up.jpg (86KB - 50 downloads)

07 Final Front View.jpg (118KB - 51 downloads)

Replacing the Windshield (Add-on): On special request here the full picture (05).

(05 All New Green Tinted Glasses.jpg)

05 All New Green Tinted Glasses.jpg (236KB - 50 downloads)

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Rear Lamp Gaskets Data Sheet: This High Precision Hydraulic Ring is no more available from the supplier. I found a similar Data Sheet as information (01) from another manufacturer.

The costs are quite high for a gasket, as it needs 4 items for a 1959 Dodge. On the other hand this material is more durable than any rubber.

The CAD design shows how the lip sets in center position of the housing (02), and how accurate this profile fits in size (03).

Mounted on the car there is a decorative distance of 6mm (04). By tightening, the outer surface of the ring becomes slightly rounded, a desirable effect (05).  - SERGE -

(01 Abstreifer Datenblatt.jpg)

(02 Rear Lamp Gasket Profile CAD.jpg)

(03 Rear Lamp Gasket CAD.jpg)

(04 Rear Lamp Gasket on Car.jpg)

(05 Rear Lamp Gasket on Car Zoomed.jpg)

01 Abstreifer Datenblatt.jpg (131KB - 47 downloads)

02 Rear Lamp Gasket Profile CAD.jpg (51KB - 50 downloads)

03 Rear Lamp Gasket CAD.jpg (75KB - 51 downloads)

04 Rear Lamp Gasket on Car.jpg (179KB - 47 downloads)

05 Rear Lamp Gasket on Car Zoomed.jpg (159KB - 50 downloads)

Convertible Top Down: Most Convertibles shows not correct setting of the top when down. Even on perfect restored cars of our challenging members (01) (02), the heighted top stands out, up to 10cm (03). This reminds the old fashioned “carriage” look on convertibles of earlier years (04).

Before restoring, the top arm of my car was as well up (05). With some effort I adjusted the mechanics for fully entering in the side box. The end of the arm now touches the body, as it should be (06). View from side, camera horizontal lined to both door borders, the top arm almost disappears (07). Then the top cover is adapted correspondingly to fit. Now it shows very flat (08).

Another harmonic car outline of designer Virgil Exner (09).  – SERGE -

(01 Nice Convertible - Gary.jpg)

(02 Nice Convertible - Mike.jpg)

(03 Top not down - Gary.jpg)

(04 Top earlier years.jpg)

(05 My Convertible Before - Top Arm Up.jpg)

(06 My Convertible After - Top Arm down.jpg)

(07 View from Side.jpg)

(08 Flat Top Cover.jpg)

(09 Review the Convertible.jpg)

01 Nice Convertible - Gary.jpg (183KB - 44 downloads)

02 Nice Convertible - Mike.jpg (185KB - 48 downloads)

03 Top not down - Gary.jpg (183KB - 46 downloads)

04 Top earlier years.jpg (128KB - 50 downloads)

05 My Convertible Before - Top Arm Up.jpg (102KB - 47 downloads)

06 My Convertible After - Top Arm down.jpg (117KB - 49 downloads)

07 View from Side.jpg (133KB - 48 downloads)

08 Flat Top Cover.jpg (114KB - 47 downloads)

09 Review the Convertible.jpg (153KB - 43 downloads)

You see absolute right, Ralf. I will come back and show some basic points how I did. There are already about 20 years since then. - SERGE -  

Foiling a 1959 Dodge: Original Danis 1959 Dodge was unicolor white (01). Then he foiled his car partly to green (02). Seeing my car live he got very impressed about this combo, so as now re-foiled green to golden (03)(03a). Another golden 1959 Dodge. Congrats to his top-job! He can redo at anytime and to any color if desired.

After getting all knights golden (04), this 1959 Dodge is on the best way to become a noble vehicle - nice to look at.  - SERGE-  

(01 Danis 1959 Dodge.jpg)

(02 Green Foiled.jpg)

(03 Foiling green to golden.jpg)

(03a Foiling green to golden.jpg)

(04 Danis 1959 Dodge Front.jpg)

01 Danis 1959 Dodge.jpg (160KB - 40 downloads)

02 Green Foiled.jpg (132KB - 39 downloads)

03 Foiling green to golden.jpg (160KB - 42 downloads)

03a Foiling green to golden.jpg (121KB - 37 downloads)

04 Danis 1959 Dodge Front.jpg (147KB - 40 downloads)

And now all done, within 24 hours - what a prospect!! Who shows next Golden 1959 Dodge?  - SERGE - 

(Danis Golden 1959 Dodge.jpg)

Danis Golden 1959 Dodge.jpg (119KB - 39 downloads)

Yes Brian. A Vinyl especial for cars, as applied on many Sport Cars. It is tricky to mount, on curves to avoid scroll must heat somewhat with a Hair-Dryer. 

Needs some practical skill, artistic vein and the motivation to go forward.  - SERGE -

Gas Spring Length 275 mm Hub 100 mm Force 200 N with Ball Head Ball Joint, Black. Style Name:275|100|200N|Black

This Gas Spring, Ralf, comes in addition to the existing Torsion Spring Bars in the trunk. Check for correct position, then drill and mount. By removing the clips it can easily be

removed and replaced. Good Luck  - SERGE - 

.

(Gas Spring for Trunk.jpg)

Gas Spring for Trunk.jpg (65KB - 21 downloads)

Amazing!  

 The flat fold-down looks wonderful

Covering the bottom fold: Most bottom folds under the sill plate look messed up, any more when they are rusty. For protection and a nicer appearance it can be coated as I did with a special black adhesive Tape 3M-33 (01). Of course, the other side of the fold must be sealed when coated, as I did with noise reduction panels on all interior surfaces, and as described earlier.

As the surfaces showed very uneven (02), I started another way by grinding the metal peaks (03), and looked for an adequate Silicone Rubber Profile (04). This, filled with black special adhesive sealant, then set on (05). The excess of glue was immediately removed, the car left for a week to dry through (06).

Now, the fold is protected, especially view from side it looks straight and neatly, as it should be all the time (07). Another “Make-Up” on my 1959 Dodge Custom Royal Convertible.  - SERGE -

(01 Fold coated with Scotch Tape.jpg)

(02 Uneven Surfaces.jpg)

(03 Grinding the Peaks.jpg)

(04 Silicone Rubber Profile.jpg)

(05 Pre-Setting the Profile.jpg)

(06 Preview.jpg)

(07 Profile Optimized and Fixed.jpg)

01 Fold coated with Scotch Tape.jpg (80KB - 16 downloads)

02 Uneven Surfaces.jpg (74KB - 15 downloads)

03 Grinding the Peaks.jpg (91KB - 16 downloads)

04 Silicone Rubber Profile.jpg (72KB - 16 downloads)

05 Pre-Setting the Profile.jpg (84KB - 18 downloads)

06 Preview.jpg (104KB - 16 downloads)

07 Profile Optimized and Fixed.jpg (93KB - 16 downloads)

I never doubt Dave, that you have a pronounced sense for aesthetics, recognizing the optical effect . . . . .  

There are various suppliers for such profiles. For your car another profile would fit better, check first the thickness of the fold.  - SERGE -

 https://shop.maagtechnic.ch/de/elastomertechnik-gummiprofile/u-profile-pr1579278053429099/?searchTerm=gummi+u-profile

just for dimensions, look at page 3

The used profile is not shown in the internet. Here a scan from the big catalogue, you will see Art. No. 122157. I think the narrow one Art. Nr. 122195 may better fit to your car. 

You will need total up to 5m. - SERGE -

(U-Profile 150.jpg)

U-Profile 150.jpg (196KB - 14 downloads)

U-Profile 150.pdf (200KB - 13 downloads)

Checking the Fuel Pump: As shown earlier, in my car I have two fuel pumps, one original mechanic and a second electrical, switchable. After about 30 sec activation of the electrical Fuel Pump, the glass fuel filter (01) becomes  full, can even hear the lower speed of the pump. Now  the car will  start up immediately. This the main advantage.

The two pumps work in parallel. Due to the non-return valves in the out port of the units, only the stronger one contributes fuel to the carburators.

My fuel line offers the option to connect a pression gauge (02). The fuel pressure of the single mechanical pump, at idle 450 rpm, is shown in (03), at 2000 rpm in (04).

The fuel pressure of the single electrical pump is shown in (05, and is independent of the rpm.

When both  pumps are active, the dominant electrical pump defines the fuel pressure. So far, just for information.  – SERGE –

(01 Glass Fuel Filter.jpg)

(02 Port for Pressure Gauge.jpg)

(03 Mechanical Fuel Pump 450rpm.jpg)

(04 Mechanical Fuel Pump 2000rpm.jpg)

(05 Electrical Fuel Pump.jpg)

01 Glass Fuel Filter.jpg (107KB - 13 downloads)

02 Port for Pressure Gauge.jpg (136KB - 13 downloads)

03 Mechanical Fuel Pump 450rpm.jpg (127KB - 13 downloads)

04 Mechanical Fuel Pump 2000rpm.jpg (135KB - 13 downloads)

05 Electrical Fuel Pump.jpg (133KB - 13 downloads)

Dual Front Door Catch System: Hitting the door to another car or wall – a big disaster due to the expensive replacement of the rare sheet metal.

This Dual Front Door Catch System, passenger and driver side, for 1959 Dodge and Plymouth (10), may fit as well for years 1956 (11), 1957 and 1958.

HighTech 3D engineered and simulated. Precision stainless steel parts, Laser cut to fit to minimum gap of 1mm. Smooth, floating roller-based operation, thus no additional door friction until snap (01). Dual trap position. First trap (02) aperture 65cm (03). Second trap (04) aperture 110cm (05). Fully opened (06) 150cm as original. Determined snap-in (07). Release force adjustable.

A unique compact set: 32 items, included stainless hex screws with matching tool, drilling template (08) and the mounting instructions. After drilled ready for mount.

An indispensable safety feature, for a valuable vehicle, avoiding damage when parking, and on slanting streets. A standard on all today’s vehicles.  - SERGE -  

(01 Top View.jpg)

(02 First Trap.jpg)

(03 Measured 64cm.jpg)

(04 Second Trap.jpg)

(05 Measured 110cm.jpg)

(06 Door fully opened 150cm.jpg)

(07 Front View CAD.jpg)

(08 Drilling Template A4.jpg)

(09 Assembled Trap Bar CAD.jpg)

(10 1959 Plymouth Door Fully Opened.jpg)

(11 56DodgeD500_4502_RightsideCourtesyLightPlunger.jpg)

(12 56Dodge Dave FrontDoorShowingDoorStopInAction.jpg)

01 Top View.jpg (128KB - 12 downloads)

02 First Trap.jpg (133KB - 12 downloads)

03 Measured 64cm.jpg (112KB - 11 downloads)

04 Second Trap.jpg (122KB - 12 downloads)

05 Measured 110cm.jpg (110KB - 11 downloads)

06 Door fully opened 150cm.jpg (102KB - 13 downloads)

07 Front View CAD.jpg (68KB - 11 downloads)

08 Drilling Template A4.jpg (90KB - 13 downloads)

09 Assembled Trap Bar CAD.jpg (75KB - 11 downloads)

10 1959 Plymouth Door Fully Opened.jpg (118KB - 12 downloads)

11 56DodgeD500_4502_RightsideCourtesyLightPlunger.jpg (114KB - 16 downloads)

12 56Dodge Dave FrontDoorShowingDoorStopInAction.jpg (159KB - 12 downloads)

Compatibilty to other Mopars: I was asked about. Here to compare, a picture with transparent front at fully opened door, and the link:

http://www.forwardlook.net/forums/forums/thread-view.asp?tid=34070&start=115

(2023-04-23 Original Front Door Stop FWL.jpg)

2023-04-23 Original Front Door Stop FWL.jpg (89KB - 10 downloads)

Checking the Neutral Safety Switch: (01) It happens once, the starter motor didn’t engage in N position. I switched the push buttons to R, then to D, and back again to N. So the starter ran and then motor as well.

To know: This device is not a switch from a classic point of view. It consists of a movable bolt as contact element, guided by the isolation, and pressed out by an internal spring. It activates the relay to the starter.

Unmounted: Whatever the position of this contact, the resistance between the wire connection and the bolt (04) should always show 0 Ohm, as well when bolt point is pressed down (02). Measured 0.1 Ohm on point, 0.00 Ohm when fully pushed in (for test). As stated, this device is not a switch, but acts as a flexible conductor, or simply a contact device. Thus, following I will talk about contact, or about safety switch.

The contact is ON when the transmission lever (03) touches the point of the safety switch, and thus the connection turns grounded. This only happens when the gear is set to N position (04). For safety, the starter motor should only work in N position. So far so good and well known. -

I did some electrical measurements on this device. from wire connection to ground (04), the safety switch always mounted, and the cable connected. Measuring Ohms the battery is disconnected:

Result should be: (Instrument checked for 0.0 Ohm at short circuit)

Position ignition switch OFF and battery disconnected:       (N) position -> 0 Ohm  (R or D) position -> High Ohm

Position ignition switch ON and battery connected:             (N) position -> 0 Volt    (R or D) position -> Battery Voltage 12V

Result was:

Position ignition switch OFF and battery disconnected:       (N) position -> switched multiple: 1.7 – 6.9 Ohm (06), but never 0 as it should show. Sometimes even up to 60 Ohm (!).

I unlocked the adjustment wheel (07) by rotating out to get the gearshift control cable somewhat movable. Now pushed it in < - > out to find minimum Ohm reading, fixed it at this optimized position.

Result Now at optimized position:

Position ignition switch OFF and battery disconnected:    (N) position -> up to max 1.3 Ohm (08)

Position ignition switch ON and battery connected:          (N) position -> starter motor will always work

This proceeding may be considered as another, simple operational check of the Neutral Safety Switch, without unmount. A way for electrically fine position the control cable to the peak of the contact lever (03).

- SERGE -  

N.B If the safety switch shows in any position 0 Ohm, resp. 0 Volt, then there is a short-circuit, and no start protection. If there is always High Ohm, resp. 12 Volt, then there is no contact at all. The car cannot be started. May be too low pressure from the bolt to the contact lever, the internal spring may be weakened or even broken. In both cases the switch must be replaced (09). By switching the gear selector (10) before starting several times from R to N and the other way back, the contact may be cleaned.

Some basics and pictures presented earlier by courtesy of Phil Courant (Phil_the_frenchie).

(01 Neutral Safety Switch.jpg)

(02 Contact Pressed in.jpg)

(03 View on Transmission Contact Lever.jpg)

(04 Electric Test Connection.jpg)

(05 PhilCourantsSafetyLeverContactingSafetySwitchInNeutral.jpg)

(06 Reading 1.7 - 6.9 Ohm.jpg)

(07 Turning out the adjustment washer.jpg)

(08 Reading max Ohm 1.3 Ohm.jpg)

(09 PhilCourantsNeutralSafetySwitch_1704283.jpg)

(10 Push Button Unit.jpg)

01 Neutral Safety Switch.jpg (81KB - 8 downloads)

02 Contact Pressed in.jpg (62KB - 8 downloads)

03 View on Transmission Contact Lever.jpg (154KB - 7 downloads)

04 Electric Test Connection.jpg (111KB - 7 downloads)

05 PhilCourantsSafetyLeverContactingSafetySwitchInNeutral.jpg (129KB - 7 downloads)

06 Reading 1.7 - 6.9 Ohm.jpg (123KB - 7 downloads)

07 Turning out the adjustment washer.jpg (69KB - 7 downloads)

08 Reading max Ohm 1.3 Ohm.jpg (136KB - 7 downloads)

09 PhilCourantsNeutralSafetySwitch_1704283.jpg (138KB - 8 downloads)

10 Push Button Unit.jpg (115KB - 7 downloads)

Color of a Convertible Top: There are two ways for select the color of a convertible top: Original color or Custom color.

When I got my 1959 Dodge Custom Royal Lancer Convertible, it had a white top, greyed-out similar as shown in (01), and partly broken at the edges. The new included white top I gave to a friend as gift, for I decided to switch to black.

Can say, never a white top on a white car, for the color will barely match, fade out in time, and show any dirt. Except to a white paint, a white top will fit to any other color. On the other side, any other top color may fit to a white car. This my personal view from an esthetical and practical point.

The black top on my convertible looks always as new, now even many years later (02)(03)(04).  - SERGE -  

(01 Convertible Top White Greyed.jpg)

(02 Convertible Top Black.jpg)

(03 Convertible Top Black.jpg)

(04 Convertible Top Black.jpg)

01 Convertible Top White Greyed.jpg (110KB - 2 downloads)

02 Convertible Top Black.jpg (142KB - 3 downloads)

03 Convertible Top Black.jpg (141KB - 3 downloads)

04 Convertible Top Black.jpg (105KB - 2 downloads)