# Gary Kuster's "Plodge" Adventures
**URL:** https://59plymouth.net/t/gary-kusters-plodge-adventures/3917
**Category:** Rebuilds
**Created:** [November 14, 2024, 10:44pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917 "2024-11-14T22:44:20Z")
**Posts on this page:** 20
**Page:** 1
### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 14, 2024, 10:44pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/1 "2024-11-14T22:44:20Z")
_Here you’ll find the detail on how Gary built his '59 “Plodge” Mayfair, “Finnegan”. Visit it in [The Showcase!](https://59plymouth.net/t/gary-kuster-regina-saskatchewan-canada/3916/1)_
Trying to decode my car and not having much luck probably because it’s a Canadian car?
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]_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 15, 2024, 10:39pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/2 "2024-11-15T22:39:25Z")
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_Arms are about to fall off from all the compounding, sanding and waxing…_
_…but there seems to be a Plodge under the dirt and oxidation._
_The roof is still the original paint and after removing the tree sap with a razor blade and compounding, it came back pretty good._
_The hood, though, is another story_
_I cleaned and sanded the hood. I removed a layer of dirt and oxidation._
_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._
_A little more progress on the front end. I’m just cleaning it up a bit for fun._
_Eventually, it will have to be stripped properly for paint._
_Hood is in primer!_
_The trunk lid will soon get similar treatment - along with the trunk itself_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 16, 2024, 9:07pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/3 "2024-11-16T21:07:16Z")
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_When I bought the car, it had black rubber flooring._
_But I could see something red sticking out where it was torn. I pulled up the rubber flooring and the red carpet was underneath._
_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?_
_The rubber keeping the carpet damp did a great job rusting out the floor._
_As they say in Nowfoundland (discussing a retrofit on a ship) "she’s rusted from appetite to arsehole" so was my floor._
_Couldn’t sleep, wandered into the garage and saw I left my trouble light on. Even looks good in the dark!_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 16, 2024, 9:18pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/4 "2024-11-16T21:18:23Z")
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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…_
_reinstalling the re-chromed bumper_
_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._
_Can’t tell me George Barris didn’t borrow the "Look" for the Batmobile from this '59 Dodge_
_Interior is pretty decent on this one. headliner and seats redone. Not particularly well, but redone. No Mice ever…_
_working dome light!_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 16, 2024, 9:33pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/5 "2024-11-16T21:33:07Z")
_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._
_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._
_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](https://www.c2cfabrication.com/). I only have to fabricate some of the rusted cross braces.
_Finished the drivers side floor!_
_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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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 16, 2024, 9:48pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/6 "2024-11-16T21:48:21Z")
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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._
_New rocker fits well and the gaps under the door are good. Lf. rear Inner fender needed some love as well._
_Skim of bondo and test fit of the chrome trim. That’s enough for today. It will stay in white primer until spring._
_Not ready for paint by a long shot, but a good 10 footer!_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 16, 2024, 10:13pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/7 "2024-11-16T22:13:01Z")
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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._
_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
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 16, 2024, 10:26pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/8 "2024-11-16T22:26:38Z")
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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)…_
_…the lower part behind the wheel and especially the top of the wheel arch. Is anyone fabbing these parts?_
_Hmmm…_
_Giving the trunk lid similar treatment as the hood_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 16, 2024, 10:34pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/9 "2024-11-16T22:34:28Z")
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_Bodywork and painting continues on the '59 Dodge_
_Drivers side is done except paint correction and polish. Time to spin it around and do the pass side._
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 16, 2024, 10:41pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/10 "2024-11-16T22:41:47Z")
_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._
_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.]_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 20, 2024, 1:09am UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/11 "2024-11-20T01:09:39Z")
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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…_
_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](https://quireyqualitydesign.com/) (who bought out Gary Goers) has 'em, along with the clips that hold them into place. -Dan]_
_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!_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 21, 2024, 4:40pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/12 "2024-11-21T16:40:48Z")
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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._
_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._
_Got the pass rear floor done today on the '59 Plodge._
_Mocked up the rocker for fun._
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 21, 2024, 4:58pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/13 "2024-11-21T16:58:24Z")
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_Done with the '59 Plodge bum. 6 week wait for the tail lights to come back from the chrome guys._
_The A body GM. trunk seal doesn’t work. I will have to find a correct seal (which I subsequently did - again from Quirey!)_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 21, 2024, 5:04pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/14 "2024-11-21T17:04:26Z")
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_Well I’m Floored. Somewhere around 60 hrs, but the floor and rockers on the '59 Plodge are done._
_The pass exterior rocker remains to be fitted, then on to the completely thrashed rt. quarter panel._
_Rebuilding all the cross supports and seat reinforcement took forever._
_…and the passenger outer rocker is done. Almost ready to start on the wheel well from hell._
_Had to support the car by the diff and the front lower ball joints to keep the body in alignment. The B pillar will droop if you’re not careful._
_Left the passenger front door on so I can always check to see if it still closes with 1 finger._
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 15, 2024, 10:40pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/15 "2024-11-15T22:40:00Z")
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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._
_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._
_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._
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 15, 2024, 10:40pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/16 "2024-11-15T22:40:50Z")
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_Purchased what I hope is the original radio for my Dodge Mayfair (Plodge)._
_It has no Chryco/Mopar etc. stickers or numbers. Just says "Deluxe" on the dial._
_Mismatched knobs as well, hope at least one is correct._
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 21, 2024, 5:03pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/17 "2024-11-21T17:03:20Z")
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_On my 59 Dodge Poly 313, I have the distributer out and I cleaned it up and will replace the points/condenser etc., but noticed there wasn’t anything resembling a seal or o ring where it goes in the engine. I’m thinking a round paper gasket of some kind should be there… Strangely, no oil leak or weep at all in that area. I did consult the Canadian shop manual for the car and it doesn’t show anything, paper or steel. I’ll give it a smear of sealant._
_Distributor is back in and the car runs so much better with new points, condenser and 4 plugs (the rest were backordered.) In the process, I mislaid the metal vac pipe from the carb to the advance so I started it up anyways to see how she runs. At idle, with a warm engine, The carb is still producing substantial vacuum. Shouldn’t the carb only supply vacuum to the distributer on acceleration. Idle is set at around 750 rpm.
I find the fact it has a steel vac pipe strange as you would have to bend it to set the timing!_
_Thanks everybody that helped me stumble thru my tune up on the 59 Plodge. Plugs showed up today, AND I found the vac pipe hanging from the snow blower handle (by accident when I moved the snow blower to the backyard shed.) Car runs amazing!_
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 22, 2024, 8:23pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/18 "2024-11-22T20:23:28Z")
_Plodge rust repair on the dog leg. Step 1, buy Rice Crispies, Eat them and use the box as a template._
_Trace out the piece to be fabricated and trace out the metal._
_Cut it and weld it in. Presto._
_Disclaimer: Not a body guy! Retired VW/Audi/ Mercedes shop owner. Just a hacker doing the best I can with what I have. I know Brass is bad, but I suck at Mig so there’s that._
Now I’m looking for a pair of rust free fender skirts for my 59 Plodge. (Same as "59 Plymouth) I need them to act as a template to reconstruct my rusted out wheel opening. Got the dog leg done. Hoping to avoid the “Hate skirts, love skirts” discussion. As close to Regina Saskatchewan as possible, as shipping would probably be pricy.
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 22, 2024, 8:25pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/19 "2024-11-22T20:25:21Z")
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_The parts for the Plodge keep showing up! The NOS (generic) seat covers came today. They have been folded up in a box for 60+ years. have to install on a hot sunny day. I hate dealing with hog rings, so I may have to farm it out._
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### Author:  [@Faulkner](https://59plymouth.net/u/Faulkner)
#### Post date: [November 22, 2024, 8:31pm UTC](https://59plymouth.net/t/gary-kusters-plodge-adventures/3917/20 "2024-11-22T20:31:15Z")
Had a chance to start on the quarterpanel from hell on the '59 Plodge Mayfair. All the rusted metal is cut out and 2 patches are in place. The area behind the wheel was much worse than it looked and the complete bottom of the quarter will have to be replaced. 1 patch above the wheel is in from behind, but not attached at the wheel well until the skirts arrive to get the opening right. Last, will be replacing the rusted metal I cut out of the inner wheel well, but that shouldn’t be too hard. So glad the other side is done!
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