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Sickboy's stuff: Ford Falcon restoration


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I would like to say that you do utterly shit work... sadly my deal with the priest to stop being such a sour old lying git precludes such a statement. So I'll tell the truth: Fantastic work! Not only must you keep it up, you must also post many many updates to this thread so that I and others can live vicariously through you.

:) 

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8 hours ago, spartacus said:

Great selection of cars there and great work going into that Falcon.

More about the AX please, when you get chance.

Thanks! I’ll present some coverage of it later this week. Until then, have some teaser shots of its French grimness.....

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8 hours ago, captain_70s said:

Man, that's some nice work...

How has a Cali car ended up so crusty though?

Believe it or not, by 60’s yank standards, this isn’t crusty. If this was from say North Dakota or Minnesota for example, you’d have no floor at all and no lower 8-10”  behind the arches. I doubt mine would have rusted so badly in the arch if it had been repaired probably in the first place.

Besides, I don’t know where in California it spent most of its life. California’s a big state; North Cali climate varies a lot from South Cali’s.

Thanks for the kind kudos all of you, genuinely flattered.

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Just read this through, top skillz Sir, although I reckon you're doing yourself a disservice by calling your labours "bodgery"!

My welding talents have long gone, and even when we were racing 20 years ago they were approximately 97.341674% shitter that this.

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1 hour ago, outlaw118 said:

Just read this through, top skillz Sir, although I reckon you're doing yourself a disservice by calling your labours "bodgery"!

My welding talents have long gone, and even when we were racing 20 years ago they were approximately 97.341674% shitter that this.

Thanks man, that means a lot. I really enjoy it. Granted, I wasn't intending that " bodgery" remark to be taken seriously 😄

I do the odd bit of this sort of thing for other people on the side , so am always happy to assist  🙂

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Thought I'd show a bit more. The door glass channels were shot to bits, to the point they were removed with a brush! Whilst making new ones I found the nylon bushes which run in the rail were worn out, so I made new ones from aluminium at the same time.

I used Tiger Seal to affix the channel to the glass.

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A few pictures of the engine, although not a lot to show yet. I have most of the jammy bits to build it now, just need to order pistons and rings. Taken ages researching the best pistons to use in terms of comp ratio, valve reliefs, ring pack, material etc. Think I'm decided on the right ones now. 

 Then I need to put my hand in my pocket for machine work.  Its in bits at the moment; I work for a machine shop / classic engine specialist so most of the bottom end is currently residing under my bench at work. A job for the winter is the plan...

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All brakes rebuilt, new cylinders and hard lines.  I also made a drain bung for the axle casing and welded that in, since these Ford 8" and 9" axles never had this provision, so you normally have to split the 3rd member to drain the oil (and yes, I decided to do this AFTER I painted it!!) 🙄

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The steering idler bracket had been bodged and bird-shit welded to the chassis rail. Not sure why,  perhaps to clear the transplanted V8's  exhaust or something since this was originally a 6cyl car.  Seeing the daft money some of them were on eBay USA for, I opted to cut this off and make one

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Finished the inner wheel tub. My homebrewed bead roller really helped make this, at it needed to be a compound curve. I had to trim more of this inner arch out than needed for rot repair (you can see the stitching in the second picture down). This was to allow access for the dolly when planishing any imperfections. I then stripped, primed and undersealed both rear tubs, and primed and chassis black the entire back side of the new rear quarter.

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Then it was onto filler work, which isn't a job I enjoy. I undertook this in dribs and drabs over the summer, to avoid driving myself mad!! I kept redoing bits trying to make them a bit better, all the while with passing mates saying "just bloody prime it!!"

But, desperate to get it in primer before the cold and damp weather set in, I finally got to this stage a few weeks ago and I epoxy primed it

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Turned out OK. I plan to get it n the road in primer then find someone to spray the top coat later on. Its been repsrayed before so I have no idea what shade red it is now

Fitted the axle last weekend :)

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7 hours ago, cort1977 said:

Looks highly professional that.

I had understood that leaving a car in primer was a bad idea as it can absorb water; I take it that's not the case with epoxy primer?

Epoxy is still porous, but a lot more forgiving than other primers. Its just until I can get it on the road and registered, it’s not a permanent state.

It will hopefully be on it’s wheels in the coming weeks and then I can start thinking about wiring and putting the interior back in......or wheel it out and get the Saab in for welding whilst I save the money for the Falcon wiring harness 🤔

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I'm looking at your work here, and thinking back over what I've been doing this summer with my Cadillac.  There's no way any of your work can be called bodging!  You are going to have a glorious Falcon when you've done.

Positively Magnificent!

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15 hours ago, SiC said:

Incredibly impressive work here! I've not had the time or energy to carry on with my Dolomite, but my work will be very embarrassing against the quality of yours!

 

2 hours ago, eddyramrod said:

I'm looking at your work here, and thinking back over what I've been doing this summer with my Cadillac.  There's no way any of your work can be called bodging!  You are going to have a glorious Falcon when you've done.

Positively Magnificent!

Nonsense @SiC, your Dolly looks like its coming along a treat! And Huggy Bear is ace,@eddyramrod,  loving it's 70's brown-ness and its great to see you're making full use of it and actually driving it ; that's what its all about.  I'd be truly proud of either project guys!!

Both of you, let me know if you need any repair sections making or fabrication doing :) 

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8 minutes ago, sickboy said:

Both of you, let me know if you need any repair sections making or fabrication doing :)

I might take you up on that for the rear wheel arch panel for it! 😀

I'll see what can be salvaged off what's there already. Hopefully I can get most of it off and made as a template, as it looks directly welded over the top of the original body. 

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Only a small, menial update. A few odd jobs this weekend. Finished plumbing the brakes. I decided the run the line from the back through the outrigger, predominately for safety to make it less prone to damage from hitting something, jacking it up etc.

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Also was a clip short to affix the front brake line to the bulkhead, so made another one rather than used a rubberised one to keep it all looking factory and consistent (told you this was a small, menial update!). This will be fitted to the RHF brake line in the engine bay, far left of the imagine below, once the heater is fitted, as it'll use one of the heater's fixing studs.

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Came to fit the rear interior quarter panels, and decided to ditch the irritating stock door card clips and use stainless rivnut inserts with countersunk screws instead. Only had two M5 inserts so ordered a few more to do the other side; should be by the weekend.

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Dug the fuel tank out too. Its still dented to buggery from the historical rear end shunt, but there's no way I'm pulling the dent since its enclosed, you can't weld to it and its super thick steel too. So plan was to just clean it, treat it inside and bung it back in. Only closer inspection showed the inside is worse than I'd hoped,  and checking to see the cost of a new tank, they can be bought brand spanking new for $90. The tank treatment is £50!! So I'll go new tank. .methinks

Had a look at the sender though, and winding's a appear to be ok, so I'll give it a chance before buying a new one.

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Fitted up the handbrake cables and filled the axle with EP90

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Deliberating which aftermarket harness kit to choose at the moment. Its the next part of the puzzle. I made the entire one from scratch in my 100E, buying each wire and and creating a diagram to suit. But the time expense, plus the fact it actually came out quite expensive compared to an off-the-shelf one, puts me off doing this on the Falcon. Bit skint at the moment though, so cost is admittedly a factor.

Dropped it back onto it's wheels to cheer myself up. First time its been off axle stands in two years!!

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  • 3 weeks later...

Some more tinkering over the last few weeks, centering on the battery box the wiring.

I'm a bit shit at wiring.  Since I made the complete harness from scratch on my 100e I admittedly now have a better understanding than before, but I'm still a novice. Time expense aside, it also ended up costing more in materials than I thought it would, probably around £60 just in wires. With the Falcon a bigger car with more circuits, I opted to buy a harness kit instead this time. I ended up buying this cheaper, unbranded UK- sold harness rather than this branded one, frankly because it looked identical in the pictures but at half the price. I suspect they're both made in the same factory.  There was little online about these and description was lacking in any technical specs, but I'm really impressed by the quality of it.  The copper in the wires is nice and thick, which is important, as often you find cheap car electrical products boast of heavy gauge wires which are just thick insulation around a thin copper core, hardly safe for much amperage.

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I'm still routing the wires at the moment, planning it all out, nothing is attached but I will use plastic trunking and nylon P clips to run the harness from the fuse box to the under dash, front and rear. I want to try and keep it all tidy

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I also made a battery box. I used 1.2mm aluminum. Still not finished, as I'm waiting on a mate for some nice brass aircraft rivets for the corners. Failing that I'll just weld it.

 

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I used my bead roller with my homemade joggle dies to put the straightening bead into the sides. Sooo much nicer to form ali than steel :)

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Had to cut a length of angle to fold up the second stage of the box

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Then I made a dimple die to make some feet for the base. This was ali too as its softer and less prone to making marks on the sheet. Ideally I'd have not done these and instead just joggled another pad into the bottom to match the sides, but if I did that it wouldn't have fitted in the metal brake!!! 

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As well as the awaited rivets for the securing the 4 corners, I plan to drill a hole in either end of that cross bar and run R-clips so it can be easily slid aside for battery removal. Of course, that plastic backing will be peeled off later to avoid scratching it whilst I'm still building

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      I'm a masochist from Leeds who is running two rusty, worn out Triumph Dolomites as my only transport in rural Aberdeenshire. You might recognise me from various other forums and Facebook groups. Realistically I need to buy a modern car of some sort, but instead I find myself looking at £300 Citroen BXs and Triumph Acclaims on Gumtree and thinking "yeah, that'd fit right in with the rest of the broken cars I can't afford".
       
      On to the cars, the main attraction being my 1976 1850HL "50 Shades of Yellow" that I bought for £850 and is currently my daily driver, here is a picture of it before I sanded off some surface rust and sprayed it badly in the wrong shade of yellow with rattle cans:
       

       
      Within a month of purchase I managed to plant it in to a steel fence backwards after a botched gear change on a wet roundabout and ruined the N/S rear wing, although judging by the other dent that's packed with filler it looks like somebody had already done the same. I also managed to destroy a halfshaft and one of my Sprint alloys (good for an extra 15hp) in the incident, so now it's sitting on it's original steelies but painted black (good for an extra 5hp).
       
      It's only broken down on me twice. once with some sort of fuel delivery related problem which may or may not have been an empty fuel tank and once when the thermostat jammed shut and it overheated and blew out some O-rings for the cooling system. It has recently developed a taste for coolant and oil which is rather annoying, although it's done 89,300 miles which is about 80,000 more miles than BL engineering is designed to last, I'm keeping my eye on eBay for replacement engines... 
      I tried to keep ahead of the rust a bit by rubbing down the arches and re-painting them, but apparently rattle can paint isn't great when you are spraying it at -5C, it also highlighted how although my car might have been Inca Yellow in 1976 it's now more of a "cat piss" sort of shade. So I ended up with the wrong shade of yellow which has rust coming back through after 5 weeks. Did I mention I'm incompetent?
       
      The other car is the first "classic" car I bought, so I can't bear to sell it. It's a '77 Dolomite 1300 and it cost £1400 (about £400 too much) and has been nothing but a pain in the arse:
       

       
      It looks much prettier (from 100 yards) but that's most due to the darker paintwork hiding the rust. It lives a mollycoddled life in my garage, where it somehow still manages to rust, and is utterly rubbish. 0-60 is measured on a calendar, top speed is 80ish but at that point it uses more oil than petrol, it rarely ventures over 50mph and if you encounter an incline of any sort you can kiss that sort of speed goodbye, along with about £20 of 20W50 as it vanishes out of the exhaust in the form of blue smoke.
       
      One of the PO's had clearly never heard of the term "oil change" so it developed into brown sludge that coated everything internally with the next owner(s) blissfully pouring fresh oil on top of it. This lasted until about 600 miles into my ownership when there was muffled "pop" from the engine bay and the car became a 3-cylinder. The cause was catastrophic wear to the top end causing a rocker arm to snap:
       

       
      As this was my first classic car I'd assumed it was supposed to sound like the engine was full of marbles, it wasn't.
       
      I put the engine back together with second hand bits declared it utterly fucked and promptly did another 5000 miles with it. After about 3500 of those miles the oil burning started, valve seals have gone so it's been relegated to my parent's garage as a backup car and something to take to local car shows as the 1850 is now embarrassingly ugly. I'm keeping my eye on eBay for replacement engines (deja vu, anybody?) Oh, I also recently reversed it into a parked Ford Fiesta and royally fucked up the rear bumper, rear panel and bootlid. Did I mention I'm incompetent?
       
      There have been two other cars in my life. My first car, a 2008 Toyota Yaris 1.0 an it's replacement a 2012 Corsa 1.4T. I didn't really want either of them, but it's a long story involving my parents and poor life choices. Ask if you want to hear it!
       
      So that's a brief summary of my current shite. If you want more pictures or details of anything do say as I've got photos of almost everything I'd done with the cars.
    • By Shirley Knott
      Greetings all.
       
      After lurking here for a short while, frankly liking what I see and enjoying the various shite, the site has well and truly struck a chord with me. I'm a serial buyer of ropey sub £1k vehicles, don't have to but genuinely enjoy it.
       
      I feel like I might (Just might) have found my 'spiritual' home here
       
      I've been posting across the web on owner specific forums (Usually using either my JoeyEunos or RandomPrecion handles) for a while now, but from here-on-in I will pull my threads together and merge them here into one ghastly topic.
       
      My current steeds...
       
      Lupo 1.7 SDI
       
      SAM_5560 by
       
      and the work/story so far...http://forums.clublupo.co.uk/index.php?/topic/102863-joeyeunoss-sdi-beater/
       
      Golf Mk4 SDI
       
       
      SAM_5531 by
       
      and the thread.... http://uk-mkivs.net/topic/597074-project-slow/
       
      Early (1989) Mk1 Eunos (This one was recently sold)
       
      SAM_4656 by
       
      the thread...http://www.mx5nutz.com/forum/index.php?showtopic=213274
       
      Other shite I've owned and moved on in the last year include this ropey Passat...
       
      SAM_6011 by
       
      and this legendary £300 Fiesta Finesse...
       
      Festa by
       
      Cars I'd like to own/actively looking for in the forthcoming weeks/months/years...
       
      Rover 75 (Dizzler)
      Peugeot 405 (XUD)
      Mk1 Octavia (Estate/dizzler, pre pd or SDI)
      Honda CRV (Gen1)
      Volvo 240/850
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