By Dan Lesser
Photos by Pat Chapin and Dan Lesser
Photo captions by Sonny Stone
Mostly everyone in our Viper Club knows the affable Dr. Jerry “2 Vipers” Tracy, MD. And most everyone knows that unfortunately, last year on his way back from VOI 9 in Nevada, Jerry fell asleep at the wheel and woke up to find himself driving under an 18 wheeler on interstate 90. Happily, Jerry escaped with a few bangs. Not so happily, his twin-turbo red SRT-10 convertible was, as they say, a little messed up. See photos 1, 2 and 3!

This is what Jerry saw when he went to pick up his Viper from the Towing company. Even Sonny Stone wouldn’t make a joke…

Welcome to hell. Ready for its close up.

Is it possible it could be salvaged? This is in Dan’s garage. Already looks a bit better than photo 1. Dan has assessed the damage and has started to work his magic!
We started the repair project in November. Jerry and I agreed on the work to be done, which at that time included the main repair, as well as extras such as chroming his HRE wheels, StopTech Brakes, Hennessey Front Bumper, and an Autoform Comp Coupe style hood. These upgrades were carefully costed into the overall project cost, and equated to a boat-load of virtually free upgrades for Jerry. All work was to be performed by myself and myself only, with the exception of the paint work which I sub out to a local paint shop.
The fun begins
The first thing was to strip the car down to a point where there was no damage. This included removing the remaining parts of the hood, fender, bumper, driver door, driver side sill, etc. Taking care to retain as many usable parts as possible such as the innards of the driver door, fasteners and so on. The 3 remaining wheels were sent back to HRE for chroming, and a new 4th was ordered. The driver front wheel was ripped clean off the car and tossed a few hundred feet from the accident. Then the driver side suspension, inner fender, Twin Turbo Piping and all of the front cooling system was removed - much of it having to be cut away, as it was crushed in place from the accident. Finally, the damaged sections of frame were cut away, from the front of the driver side suspension to the passenger headlight, as well as the jack-point beam directly behind the driver front wheel.
At this point, all that was remaining was a generally good condition platform to build on, with the exception of a slightly out of alignment front frame section, and a few other odds and ends that needed to be straightened out. At this point, a number of hydraulic frame-straightening tools were needed to push/pull the frame back into a rough alignment by going over the frontal measurements one by one. The new frame sections, acquired from a donor car were then cut to size, and TIG welded in place. After this, a final adjustment of the frame sections was done. NOTE: I prefer to wait until after welding for final adjustments, as the high heat has a tendency to change the angle of the beams ever so slightly, especially on butt-welds. I also prefer to TIG weld as the strength compared to MIG or Stick welding is exponentially greater and much more controlled.
Finally, the frame sections were put to the test to expose any potential weak spots (which aren’t expected when TIGing, but worth the check). This includes pushing/pulling the rails hydraulically, as well as lifting the car from the rails outermost points, and even bouncing the car to attempt to show a weakness. 100%+ of the frontal car weight was successfully supported by both the jack-beam, as well as the front headlight beam - both which would never see these stress levels in normal use. After everything passed QC, the frame sections were roughed up sanded if needed, and painted.
After the frame, I straightened out Jerry!
Well, Dodge Viper screaming red is just a little calm for Dr. J - so it was about at this point that I helped him decide to change the color of the car - screaming Lamborghini orange! As well, we chose to replace some slightly damaged paneling with new parts instead of repairing them. As such, all remaining body panels were stripped from the car and dropped off to the paint shop along with the new ones. It was determined it was best to paint the car while it was completely apart: this also allowed me to repair the car at the same time the painting was being done, speeding up the progress. Aside from a few holdups due to back-ordered panels, it went pretty smoothly considering the scale of the rebuild.
At this point, the underbody assembly began. The new inner fender was fitted and glued to the frame, and all components which are fitted to that panel were reattached. Some modifications were also performed at this point, such as powder-coating of the intake manifold, and changing out some of the hoses on the car with Stainless Steel lines (the lines supplied by RSI, the turbo installers, were already falling apart.) The front cooling system was also replaced in its entirety, as well as any damaged lines, we added a new hydraulic fan and shroud. The new headlight, ABS Hydraulic Unit and PCM were attached, and all the wiring was repaired. About this time, the interior of the car was also stripped out. Jerry first opted to have the seats recovered in Canadian beaver pelts, but we talked him into leather. As well, we replaced the interior bulkhead panel behind the seats as the fitment of the Autoform panel was very poor. I modified an OEM panel to work with the roll bar, as well as corrected the seatbelt corner anchors to the belts so they retraced correctly, fabricating and TIG welding new brackets onto the roll bar.

| Beauty shot of Jerry in his better-than-ever ride |
Beauty shot of Jerry on his better-than-ever prescription muscle relaxants. |
| |
How to get out of tickets while driving other people’s cars!
The freshly painted panels started coming back soon after, and the car was assembled from the rear moving forward up to the rear of the doors. The front suspension was then completely replaced, the Stoptech brakes/EBC Red Pads were installed, and the rear wheels which had just come back from HRE were put on, giving us the first glimpse of a "Viper" again... or at least the back of one! The orange color, ‘Arancio Atlas’, gave its first sneak peak the next day when the sun came out - and WOW what a color! The Turbo Piping and the re-cored intercooler were also installed soon after. Lastly, the doors & seats were reassembled and installed, and the front fenders and side sills were fitted after repairing the side-sill bolt holes which were all ripped apart during the accident. At this point, the car was driveable, but without a hood and bumper, which were being finished up at paint and were too big to transport after paint as they could not be crated or moved without fear of scratching. In the mean time, the car was aligned, inspected, computers were reprogrammed, and the driveability of the car was double checked. The car performed so well... that I got a damn ticket in it within 1 mile of getting on the highway. Luckily, being in my position and driving a car that was unfinished made it easy to plea the fact that the speedometer wasn't functioning correctly, and I get let off with a "fix-it" ticket. (Phew!!!)
Finally, after everything else was worked out, the car was brought to the paint shop, where the details were touched up, the hood, bumper and decals were installed, and the car was finish buffed. It was at the paint shop where we got our first good look at the new car- and what a sight it was, almost hard to believe it looked like it did 6 months before! Aside from a few small details that were still backordered, the car was complete and ready for Jerry to take possession of it. Short of a couple lingering issues from before the accident which were long forgotten about and since repaired, the car has performed at 100% and hitch free since it was reacquired... I am not surprised, but most are when they see what the car used to look like!
Jerry and I have since been talking about taking this car to the next level and get the most out of his Twin Turbo system. I look forward to sending you another write-up next year!

Hennessey’s SRT fascia. Most Ontarians think Nabil has a better looking face.

Super clean work in the engine bay.

Pat Chapin’s heroic overhead shot of Jerry and Gail and their beloved Vipers. After months of worry, Jerry found his gold (or at least his screamin’ honkin’ orange) at the end of the rainbow.
EDITOR’S NOTE: I hope you readers enjoyed the story of Dan’s detailed repair and restoration. I have had Dan do a few things on my Viper as well, and I encourage our club members to patronize his business. It’s an easy drive down to Buffalo. Besides major repairs and custom works like Jerry’s car described here, Dan is particularly good at fixing and adjusting minor bugs that often dealers just can’t offer the resources to fix. You can reach him at 716-912-5336. The name of his company is Viper Specialty Performance and he’ll always be glad to answer your questions and to talk Vipers.
----------------------------------------------------------------------------------------
|