1963 Ford Falcon

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1963 Ford Falcon

Post by 63Falconconvert on April 5th 2011, 8:19 pm

Finally after being on this forum for 2 years Iím finally getting the time to paint my Falcon. We got the car 4 years ago off of eBay. I pulled the original 170 straight 6 and rebuilt a 1966 200 straight 6 I got out of a Mustang. Next was the transmission, I replaced the original 3 speed with a C4 from the same Mustang donor car. To make the car look correct I swapped out the 3 speed steering column for an automatic shift column along with the correct brake pedal assembly. A few other fixes to get it road worthy was a new wiring harness under the hood, an alternator in place of the generator and new shocks. 4 years later and 6000 miles the car has been totally trouble free. One of the past owners painted the car in enamel, replaced the rear quarters, basically threw the car together. The quarters are fixable, but the trouble spots are the driver side inner fender and the trunk drop downs. So before I can paint I have a lot of metal patching to do. I started in the trunk, removing the rear bumper, pulling out the gas tank, grinding off the old paint in the trunk. I welded in 3 patches in the trunk, 1 small patch and 2 around the driver side wheel well.



holes in the trunk
]
patches in the trunk

looking from underneith on the driver side, inner fender, fender lip and trunk drop down. Someone had riveted some patches in, more like scabbed them in. When I removed them this is what I found.
Fender lip looking toward the rear of the car:

trunk drop down

and inner wheel well....what a mess!

passenger side rear fender lip

and the drop down:


so as you can see I have a little work to do. I started on the pass side cutting out the the rest of the rot and making card board templates and cutting out patches. I'll post somemore pics tomorrow.
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Re: 1963 Ford Falcon

Post by rmdhokie on April 5th 2011, 8:48 pm

Very nice Falcon! I'll be following this thread. Good luck!
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 5th 2011, 11:09 pm

thanks....it will be a challange... ahhh
I was able to get a little time tonight to cut out more metal.
Cut out a small portion on the inner fender and most of the trunk drop down:

Looking from underneath:

As you can see the replacement quarter was put right over the original. The right way to fix this is to cut both of them off, but at $200 a side I'll fix these. I have to remember that this car is a driver, not a show car. I'm going to tack down the original quarter to the new quarted and seam seal it.

This is looking from inside the trunk:

From the back, you can see where the drop down was cut out, I still have a little trimming to do to get my new piece to fit.

This is the drop down piece. It's hard to see on the original piece the 2 1-1/4" wide ribs. I tried to recreate those on the new panel.
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Re: 1963 Ford Falcon

Post by snafu on April 7th 2011, 1:15 pm

Love those roundbody Falcons!

Are you going white again?
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 7th 2011, 1:28 pm

yes, bright white. I'm thinking of doing red scallops on the hood.
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Re: 1963 Ford Falcon

Post by T.Hadley on April 7th 2011, 7:43 pm

Glade to see you got started, lots of rust there, but the old falcons had some good metal in them, it should weld up nice.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 9th 2011, 4:24 pm

Finally a warm day, almost 60 degrees! Got all of the cardboard templates made this morning for the passenger side. I'll transfer the patterns to my sheet metal and then plasma cut the shapes out. Trying to get the inner fender, the entire bottom of the fender and the lip to all come together was a challenge. I should have some pics tomorrow.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 12th 2011, 9:15 pm

Got some patterns cut and shaped on the passenger side inner fender.

Cardboard templates


Plasma cut the shapes out of 18 gauge


I don't have a sheet metal brake to make nice tight bends so what I do is cut notches with a fine cut off wheel, make the bend then fill the notches with weld and grind to clean up:



Clamping the pieces into place:




Once I get all of these pieces welded in then I can make the piece to tie in the fender to the drop down and the fender lip.
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Re: 1963 Ford Falcon

Post by T.Hadley on April 12th 2011, 9:41 pm

Nice, Looking good...
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Re: 1963 Ford Falcon

Post by steveringer08 on April 12th 2011, 9:48 pm

thats quite the collection of vise grips if i do say so myself.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 13th 2011, 8:35 am

T.Hadley wrote:Nice, Looking good...

Thanks, I use your pics as reference all the time, you make rust repair look really simple.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 13th 2011, 8:42 am

steveringer08 wrote:thats quite the collection of vise grips if i do say so myself.

LOL....thanks, I work at a welding supply store, we sell all kinds of welding supplies, specialty gasses, propane, medical gasses, etc so I can buy all of my tools at 5% over cost. Every week I come home with new "toys". My wife also works here, she does all of the purchasing so see gets to order all of my stuff. I'm like Hank Hill, "I sell propane & propane accessories"
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Re: 1963 Ford Falcon

Post by rmdhokie on April 13th 2011, 6:29 pm

What kind of discount do Rolled On forum members get on welding tools? Kidding...wish I knew how to weld. You're making good progress. Keep posting pics!
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Re: 1963 Ford Falcon

Post by Tommy Hillbilly on April 13th 2011, 9:16 pm

Yeah, props on the metal work! I look forward to the day when I can do that, and leave the bondo for the small stuff. You shoulda seen the bondo job I did on my old Cougar...

rmd, it's as simple as buying the equipment, doing some google research, and then some trial-and-error on some scrap metal... That's how I plan to get started. Only experience will make any of us good at welding.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 16th 2011, 1:58 pm

Was able to get some welding done this AM.
Trunk drop down:


Inner fender extension:


I still have to make a piece it fill this in and for the fender lip:


I still have to grind the welds better, seam seal, undercoat and hopefully it will look halfway decent.

Welding on your back bites, I have a foam block that I use to rest my head on when I'm working (not welding) underneath the car, well I forgot my head was on it when I started welding...yup set it on fire, that gets the heart pounding early in the morning.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 19th 2011, 7:23 pm

Was board at work today so I brought in my gas tank, wire brushed it, primed and painted it with some Rusto metalic silver paint.
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Re: 1963 Ford Falcon

Post by Tommy Hillbilly on April 19th 2011, 8:37 pm

Tank looks good!
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Re: 1963 Ford Falcon

Post by rmdhokie on April 19th 2011, 8:50 pm

Nice job on the tank; it looks brand new.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 20th 2011, 7:32 am

Thanks....I still have to paint the other side and then clear coat the tank. As Retired Plumber talked about on another thread the silver metalic does rub off. The tank had a lot of big dents in it. I was able to use a wooden rod through the sending unit opening to pop out most of them. The tank is spotless inside so for that reaseon I decided to keep it instead of spending $300 on a repop.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 22nd 2011, 11:34 pm

Tonight I got the bottom piece welded in.




Still have to make this piece to finish off the fender lip.
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Re: 1963 Ford Falcon

Post by 63Falconconvert on April 24th 2011, 5:55 am

more holes..... affraid
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Re: 1963 Ford Falcon

Post by T.Hadley on April 24th 2011, 3:32 pm

They say rust never sleeps and I have found that to be true, just when you think you have it all you find more.

Keep the pics coming
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Re: 1963 Ford Falcon

Post by 63Falconconvert on May 8th 2011, 9:42 pm

Not much new to report. I started on the driver side cutting out all of the rusted sheet metal, making patterns and bending metal. Tomorrow I will be welding in the new pieces. The repaires on the driver side are basiclly a mirror of the pass side other then inner wheel well is a bit more rusted.

This is all of the metal I cut out of the real inner fenders and trunk drop downs.

A few of the products that I have used or will be using. The Lab Metal we sell at work. I use it over welds. It dries rock hard and is good to fill in pin holes. The Bed Coating I'll use instead of undercoating. A few of the guys on the Falcon Forum I'm on have used it with great results
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Re: 1963 Ford Falcon

Post by retired plumber on May 10th 2011, 12:10 am

Hi Falcon
I take it your repaint was a bit more than a scuff and roll job. lol! . Props to you for doing the job properly. You definately will have a car you can be proud of when you get it finished.
Mike
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Re: 1963 Ford Falcon

Post by 63Falconconvert on May 12th 2011, 8:12 am

Thanks Mike. It's getting there. I got the driver side inner well all welded up last night. Laying on your back jammed between the fender and the rear end trying to weld is no fun. For once in my life I'm glad I'm only 5'8" and 150 lbs. lol!
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Re: 1963 Ford Falcon

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