61 Falcon.

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61 Falcon.

Post by dean_af on May 29th 2011, 3:00 pm




Purchased and used as a daily driver for a few years. Low mileage 44K. Had the original tires and a set of new snow tires in the trunk. She looked not bad but, we soon discovered the rust and bad body work someone had done.
I will post pics of my work as I go. First time welder so... I'm learning as I go.
63Falconconvert has been a big help. I have been using his pics to try to figure out pieces that have rusted away to nothing.
It will again be a daily driver and possibly used in the winter. This will NOT be a show car. I have a few crazy ideas that I might try. Time will tell.

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Re: 61 Falcon.

Post by retired plumber on May 29th 2011, 5:10 pm

I really love these round bodies. What are your crazy ideas? Sounds interesting.
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Re: 61 Falcon.

Post by dean_af on May 29th 2011, 5:31 pm

Nothing too crazy but... I'm thinking about going with suicide doors. I want to keep a 6 but I'm thinking a 300ci. Side pipes and an exhaust cut-off with the headers exiting through the fender with a flame thrower kit installed.
The motor and exhaust ideas courtesy of this vid,
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Re: 61 Falcon.

Post by retired plumber on May 29th 2011, 7:17 pm

I have read where the 300 six is two tall to fit without a hood scoop. It can be done tho. There are several falcon forums and you might want to check them out and ask for info for that swap.
Also, suicide doors are really a pain in the butt to do unless you have some body work experience and are a good welder. Again, there are many good custom car web sites that discuss these mods. jalopyjournal.com is a good one. Sounds like quite a project. Best wishes and good luck.
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Re: 61 Falcon.

Post by dean_af on May 29th 2011, 8:14 pm

I heard that too about the 300. I figure a huge hole in the hood might look cool? I thought about a 302 but everyone has done it.
With the doors, I admit I'm not overly confident. I will check the jalopyjournal and see what I can come up with.
Thanks.
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Re: 61 Falcon.

Post by Tommy Hillbilly on May 29th 2011, 10:15 pm

An EFI 300 (4.9) with a turbo would be cool...
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Re: 61 Falcon.

Post by dean_af on May 29th 2011, 10:49 pm

Tommy Hillbilly wrote:An EFI 300 (4.9) with a turbo would be cool...
That would be cool.
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Re: 61 Falcon.

Post by dean_af on May 29th 2011, 10:55 pm

To show how bad the rust is. Inner splash shields.

Made new ones.
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Re: 61 Falcon.

Post by Noah Zarq on May 30th 2011, 11:08 pm

dean_af wrote:Nothing too crazy but... I'm thinking about going with suicide doors. I want to keep a 6 but I'm thinking a 300ci. Side pipes and an exhaust cut-off with the headers exiting through the fender with a flame thrower kit
The suicide doors are a lot of work, but if done correctly are pretty cool. The whole exhaust through the fender sounds dangerous, not to mention just flat-out dumb looking on this kind of car. These round Falcons look and handle well with just a simple lowering job and larger tires. The other things you describe sound a bit garish. But it's your car to ruin if that's what you want. Please oh please don't paint it satin black with red rims like 100,000 other cars out there. At least give it that much dignity.
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Re: 61 Falcon.

Post by dean_af on May 30th 2011, 11:42 pm

Noah Zarq wrote:
dean_af wrote:Nothing too crazy but... I'm thinking about going with suicide doors. I want to keep a 6 but I'm thinking a 300ci. Side pipes and an exhaust cut-off with the headers exiting through the fender with a flame thrower kit
The suicide doors are a lot of work, but if done correctly are pretty cool. The whole exhaust through the fender sounds dangerous, not to mention just flat-out dumb looking on this kind of car. These round Falcons look and handle well with just a simple lowering job and larger tires. The other things you describe sound a bit garish. But it's your car to ruin if that's what you want. Please oh please don't paint it satin black with red rims like 100,000 other cars out there. At least give it that much dignity.
lol Wait a sec... Should you use words like, "Dumb", "Garish" and "Dignity" when you own a 92' Nissan? lmao

It will be black with red rims. j/k I'm looking at Apple green the Germans used during WW2 or Luftwaffe Blue. Nothing 100%, open to ideas.
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Re: 61 Falcon.

Post by Noah Zarq on May 31st 2011, 1:54 am

Now the apple green would be pretty sweet!
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Re: 61 Falcon.

Post by dean_af on May 31st 2011, 7:30 am

Noah Zarq wrote:Now the apple green would be pretty sweet!
I think so. I'm trying to use a low gloss paint so my mistakes aren't so obvious. I'm also trying to avoid black and the "Rat Rod" look.
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Re: 61 Falcon.

Post by 63Falconconvert on May 31st 2011, 10:03 am

Nice looking Falcon! Lower it a few inches give it some new paint and new rims and call it a day.
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Re: 61 Falcon.

Post by dean_af on May 31st 2011, 10:52 am

63Falconconvert wrote:Nice looking Falcon! Lower it a few inches give it some new paint and new rims and call it a day.
lol. Sounds good. I did the Shelby drop since that pic. I still need to find rims for it that will fit the bolt pattern. I would like factory style rims, just bigger.
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Re: 61 Falcon.

Post by 63Falconconvert on May 31st 2011, 12:46 pm

I have 4 Mustang II aluminum 5-slot rims that I had a machinest buddy redrill the mounting holes to fit the 63. They are still a 13" rim. Not much out there to fit our cars unless you change over to 5 lug.
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Re: 61 Falcon.

Post by rmdhokie on May 31st 2011, 6:33 pm

dean_af wrote:...I did the Shelby drop since that pic.

I did the Shelby drop on my car as well. Great mod with noticeable improvement in handling.
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Re: 61 Falcon.

Post by Tommy Hillbilly on May 31st 2011, 11:08 pm

63Falconconvert wrote:I have 4 Mustang II aluminum 5-slot rims that I had a machinest buddy redrill the mounting holes to fit the 63. They are still a 13" rim. Not much out there to fit our cars unless you change over to 5 lug.
Did he enlarge the hub hole or the lug holes? The hub? The reason I ask, is that wheels are either "hub-centric" or "lug-centric," when it comes to balancing them or mounting them on the car. You don't want to throw that off. I know that this issue can come into play when swapping wheels on Fords.

rmdhokie wrote:
I did the Shelby drop on my car as well. Great mod with noticeable improvement in handling.
Didn't Ford start doing that to all Mustangs at some point? I thought that they were doing that by '67 or '68. You're talking about the upper control are mounting points, right?
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Re: 61 Falcon.

Post by 63Falconconvert on June 1st 2011, 8:19 am

Did he enlarge the hub hole or the lug holes? The hub? The reason I ask, is that wheels are either "hub-centric" or "lug-centric," when it comes to balancing them or mounting them on the car. You don't want to throw that off. I know that this issue can come into play when swapping wheels on Fords.

The wheels are a 4 lug, so he located the center and drilled a new hole pattern 45 degrees from the original pattern. I will be using lugs that are sleeved so the lug will slide into the new hole similar to an old style Craigar set up.
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More pics

Post by dean_af on June 1st 2011, 12:09 pm

Trunk drop-off


New metal
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Re: 61 Falcon.

Post by 63Falconconvert on June 1st 2011, 12:24 pm

nice job!...man that looks all too firmiliar....lol
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Re: 61 Falcon.

Post by dean_af on June 1st 2011, 7:53 pm

63Falconconvert wrote:nice job!...man that looks all too firmiliar....lol
I'm VERY new to welding. I made a few mistakes and it took forever to rip apart so... I think my welds are pretty good?
I'm guessing our rust patters will be similar? Wend I seen your drop-off I thought the same, looks familiar. lol
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Re: 61 Falcon.

Post by tbirdsps on June 6th 2011, 3:11 pm

You do learn by doing. Your welds look pretty good to me.
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Re: 61 Falcon.

Post by dean_af on June 6th 2011, 9:54 pm

tbirdsps wrote:You do learn by doing. Your welds look pretty good to me.
Thanks! I'm learning on areas of the car that don't show. Smile
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More work.

Post by dean_af on June 9th 2011, 3:53 pm

After removing the front fender, all the metal was gone.
I didn't take a pic at first. This is after adding a piece



Welds are strong but not that neat. I was not using gas (outside)


Added new metal to replicate what was there based on pics


Cleaned up. Shape is close. I used 18g metal and formed it with my hands. lol You work with what you have.

Everything will be done in brush on undercoat. None of this will show.
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Re: 61 Falcon.

Post by 63Falconconvert on June 9th 2011, 4:05 pm

Nice job thumbs up 18 gage is "fun" to work with.
I just got some brushable seam sealer from the local auto body supply shop, man that is nice stuff. It's like liquid rubber plus you can paint over it too. I'm sure I will find the same cancer when I pull my front fenders off.
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Re: 61 Falcon.

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