Projects 61 Falcon - Father Son Project

I'd set it for the recommended 6 degrees BTDC.

 

Yup! Thats exactly what we did!

 

will do! Thanks!

 

I went to adjust the distributor to 6 degrees today and it will only let me turn it to 12 before it hits the block. Can I pull the distributor and turn it 1 tooth to fix this issue? Which direction should I turn it.

Also, it still has heat creep. We can only go 3-4 miles before it reaches 230 degrees. I will have to get a radiator for it. They have 3 row aluminum for about $150 on Amazon, but they all say V8 only. I dont see why it would only be for a V8. Even with teh extra thickness of the core, there is enough room...

Here is an example... https://www.ebay.com/itm/312853376141?_trkparms=amclksrc=ITM&aid=111001&algo=REC.SEED&ao=1&asc=20160908105057&meid=7832404d7aac4d06bcb00ec2a48df397&pid=100675&rk=5&rkt=15&sd=115490917679&itm=312853376141&pmt=1&noa=1&pg=2380057&brand=Custom&_trksid=p2380057.c100675.m4236&_trkparms=pageci:3554f3c3-24df-11ed-a600-8e8476eda69e|parentrq:d7c928c11820a9b13e180ffefffdf3ac|iid:1

 

Easier to shift plug wires

 

wow. I never thought about that.

 

Ya might be "safe" and.....fine "absolute TDC" (with a piston stop) and mark that balancer(or verify the pointer and TDC mark!)
Then......pull the distrib and re-stab it making sure the pointer is pointing to the No.1 spark plug terminal giving yourself plenty or room to twist the distrib..
I WOULD....advance it a few degrees above factory recommendations.....8-10 BTDC maybe.
Turn it until it rattles when going up a hill then turn it back a couple degrees giving you max safe advance.
6sally6

 

We got the new radiator put in today. We had to do some slight modifications to get it the right distance from the fan, but the temp is 175-180 moving and 185-190 sitting at a light, and it was 90 degrees today...



My son just started 9th grade, and he is in Home School. So we can count working the falcon as shop class!

Tomorrow I hope to adjust the timing, as it was pinging a tiny bit today. Also, when it gets hot it makes a whistle sound, so I need to track that down...

 

Let's talk carburetors for a minute....

Im pretty sure I've found all the vacuum leaks, and the timing is set to 8 or 9 degrees BTDC. The car still wants to die if the choke is all the way in, but it's fine if the choke is pulled 1/8th inch. The idle is about 600 when I'm stopped in gear, but it goes way up in neutral. Also, last night, when I turned off the car it gave a bit of a backfire, not a full bang, but more of a large exhale out the carb.

I wonder if the air fuel ratio is off? Or if there is something I am not considering?

 

Small Update. I 3D printed a fan shroud and put it in. I used ABS so it should take the heat no problem. We also drained the radiator, put in water wetter and anti rust, and then filled it with straight distilled water. Hopefully it wont overheat at stop lights anymore.

 

Nice job on the radiator shroud! Love the continued Millennium Falcon reference!

 

So we have been driving the Falcon a lot. It’s running really good, as long as we leave it about 1/4 choked. So there must still be some vacuum leaks.

The thing that is concerning me now, it that it grinds a bit when shifting into reverse. The fluid level is good, and it’s only been the last week or so that it’s been grinding into reverse.

Any ideas what it could be?

 

Is that a proper PCV valve in the front hole of the manifold, or just a hose barb?

If it is idling too high when it is not in gear, it could make smooth engagement more difficult. Reverse is not generally supposed to be jammed into with the engine revving.

 

What I have the arrow pointed to is a spark control valve, or SCV. That is what controls a Load-O-Matic distributor, which, I believe, we have determined that you do not have.


It also appears that you have the vacuum advance line for your distributor connected to the fitting that is controlled by the SCV. That will not work properly. It will cause timing issues.

For a quick check, pull the vacuum advance hose, and cap that steel line. See of you get an improvement.

If you do indeed have a conventional distributor, you need to connect the vacuum advance to manifold vacuum, and pinch-off, or plug that metal line.

 

Thanks for the replies!! I am not sure if thats a PCV or not, Ill have to check. And I will make those vacuum changes you suggested.

The idle in neutral isnt very high. I dont have a tach hooked up, but it sounds to be 6-700 ish...

 

You can get a timing light with a tach in it for not not too much coin.

In the mean time, set the idle so that it barely creeps in gear, with the brakes off.

If it is not a PCV valve, then one from a 1990 Camaro should fit in there. That's what I run on my 200.

 

Thanks! I’m hoping to have some time to work on it this weekend.

 

Welp, we have not had time to work on the Falcon, but we are headed to SEMA this week! It will be my Sons first time at the SEMA show. Im sure he/we will come home fired up to dive into the interior of the car.

We plan on having the Falcon at the Mooneyes show in January.

 

Well, SEMA was a lot of fun, and now its time to get back to work on the Falcon.

We got the front seatbelts installed so far this week. They turned out GREAT!



Next it ordering the rear seatbelts and starting to figure out a wiper motor solution.

 

I have a Newport Engineering motor in mine, with the intermittent knob, with washer control.

I would probably be an easier install for a 9th grader than an older dude like me, but it bolts tight in. No fuss.

Two bolts. No linkage shenanigans. It plugs into the OEM linkage like a Lego.

There is a little knob extension that will allow you to use an original knob, too!

https://newportwipers.com/product/1960-62-ford-falcon/#wiper-motor

Yes, it does cost some coin, but it is well worth it!

 

Ya I saw that one. Its a bit pricey. Im thinking of just getting a universal wiper motor and 3D printing a mount for it. I can make it in ABS or Nylon so is should be strong enough... I want to pull the stock one out first so I can get a good idea of the linkage , etc.

 

That's just it. The linkage is on the firewall.

Look at the Newport picture. You will see a shaft sticking out of the****embly, with a rectangle on it.

That's the whole thing. The rectangle sits in a receiver on the linkage.

 

We’re going to see if we can rebuild the stock wiper motor. The gasket was torn, so we scanned it and 3D printed another in urethane….

 

Small update, we have been working on getting the rear seatbelts in. They are just about done, but we are going to make the package tray before final installation. We used heavy wall 1" angle iron to mount the retractors, and the belt guides.



On another note, my son has been taking some shop classes. They taught him how to weld. I was shocked when I saw how well he welded this pie cut we had to make in the angle iron. Not perfect, but pretty good for a kid just learning!

 

Yes. Not perfect as there is some porosity evident but keep him at it. Encourage him and show him ways to improve and he will excel. Never tell him it is sloppy and show him how to do it right. Tell him what he is doing wrong and guide him in proper technique and let him do it over and over again. Practice makes perfect and he is not too far from that now.

 

The interior is starting to take shape. This was the first time I have ever covered something in Vinyl. So my son and I both learned something new...

 

We have the seats in now... Next is door panels...

 

Here is a cool little update. The 3d printed gaskets worked in the vacuum wiper motor! So now we have working wipers for almost $0!

Here is a video if anyone wants to see it in action...
https://youtube.com/shorts/RLMpHnF3j7A?feature=shares

 

We had a great time at the Mooneyes show on Saturday. The Falcon made the 75+ mile trip without too much trouble. Strangely, it wanted to overheat on the drive up, if we went over 50, but on the drive home it barely got over 160 degrees. Im not sure what that was all about, but either way it was a great day!

We met up with some great friends, and one of them is going to give my boy a 302 with an AOD for the Falcon. It's a 74, smog motor, which means low compression, but we are thinking of bumping the compression. or maybe doing a turbo setup. Either way, it will be a great learning experience for my son!

 

You will be into some metal work to get the AOD in there. The existing tunnel is not large, and that transmission is.

It is worth the work.

The rear axle will not be happy with the new power, though. A 1983-1992 Ranger 7.5, or 8.8 is 1/2-inch wider than the stock rear axle. I have an 8.8 in my '60.

Be very aware that 6-cylinder Falcons were made with thinner metal, and fewer layers than the later V8 cars.

You should, at minum, add subframe connectors. I have Global West 916 subframe connectors in my car, which took a little fiddling, because even a 1960 and early 1961 are different than a late 1961. The subframe rails are shorter, necessitating that the bench seat braces be trimmed for the curve of the subframe connector tube.