Projects 61 Falcon - Father Son Project

I have a '60 Falcon ex race car- they are under-rated as to their promise of fun, and quite light weight. Favorite blue too. My Dad hated cars-had to do it all on my own. Newc

 

Two separate electrical systems.

1. If your stock Falcon used an instrument panel voltage regulator (reduces 12 Volts to approximately 6 Volts - the 6 Volt stock gauges were not redesigned for 12 Volts), you still need an instrument panel voltage regulator. The exception is if you replace the stock gauges with 12 Volt aftermarket gauges.

2. The internally regulated alternator charges the battery - the electrical system remains 12 Volts.

Russ

 

Thanks Russ! That makes sense.

 

Friday was a very productive day!

We got the instrument cluster all wired up. I didn't like the stock wiring that had 1 light for both turn signals, and 1 light for the high beam indicator. So we wired it to have 2 turn signal indicators, and we are using the voltage idiot light as the high beam indicator. I'll have to figure out a new label for the light. We will be using a Voltage gauge instead of the light.

I promise that all these wires got zip tied into a nice clean harness...

We tested the gauges with a 3v source, and they all work. When we tested the voltage reducer, it had the same voltage on both sides, so we got a new one. The new one does also has the same voltage on both sides when tested. So maybe the old one wasn't bad, but we got a new one either way.

Next up, we tackled the steering column. It was a pain, but we got it together.



We ended up having a part left over. Im pretty sure its the turn signal cancel lever, but I am not really sure where it goes, or how it works.



Also, There is a gap behind the steering wheel. Do we just need to tighten it more? (I'll 3d print a shift indicator needle at some point...)



This is where we ended up for the day. Does anyone have a suggestion for a horn ****on? From what I understand we can use any ford town ****on ***embly until 74. I also could really use a good exploded view of the horn ****on and how it works.



Next up we need to hook up the turn signal wires under the dash, then it will be time to fire it up, and let it warm up. Then we need to get some junkyard parts for the power brake conversion.

 

I believe the stock horn ****on also has a horn ring. Mine was sticking so I tore it off. I wonder if that's common.

 

Ya, there is a horn ring stock. I dont really see a need to spend close to $90 on a new one when a standard horn will work fine.

 

Also quoting the questions, "Does anyone have a suggestion for a horn ****on? From what I understand we can use any ford town ****on ***embly until 74. I also could really use a good exploded view of the horn ****on and how it works."
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This isn't exactly what you're asking for, but maybe it gets things closer. I don't know what you mean by 'town' in "any ford town ****on ***embly until 74."

Hmmm, my 61 Ranchero has a horn ****on without a ring.

 

Have you considered doing that Karel Shelby front suspension modification???

 

That wheel and ring are pretty common, they were used on pickups and fairlanes I believe. You Ford guys correct me if Im wrong.
My last project was a 1962 Falcon Futura, found it in a garage in Woodbridge Ca. Very solid as it had set inside for a great while. Great little cars for youngsters to start with. A m#$?#$g three core radiator will fit if you move the brackets on the tanks slightly (unsolder and resolder)
Have fun!

 

Thanks for the replies!

Sorry. The word TOWN should be HORN. I must have misspelled it and the computer changed it to town.

Ya we will do the Shelby drop once we can drive it and see if there are any other steering or suspension parts needed.

 

Bronco, as well. Both available as reproductions.

 

When I had my Falcon with the Shelby drop, I was always trying to figure out how I could use a steering rack rather than the old original setup.
Even a power rack if turning got too heavy.
I have a shoulder injury that is always a concern for me...

 

I have a Borgeson power box in my Falcon.

It took some fab to get it in, but it works great.

 

Has anyone tried the (O/T) Prius electric power steering on these Falcons????

LynnW

 

is the power steering 12v or part of the high voltage hybrid system?

 

For clarity, I will respond to my own comment.

The box bolted right in, as did the pump. Easy peasy.

The fab part was the bottom of the column, and the u-joint.

On the round body Falcons the coupling point is half inside, and half outside the firewall.

My solution was to use a u-joint instead of the rag joint, and to build a column reciever and mount, out of a chunk of column sleeve and a clamp. It has access holes to get to the upper set screw and lock nut.

 

Quick post...

The gas cap on this car is a bit of an eyesore. Locking caps in general aren't great looking. BUT, seeing as how a teenage boy will be driving this, and it's a FALCON, I 3D printed this gas cap cover. My son LOVES it...





The hole in the center is for the key to take the gas cap off. Ill get some pics of it on the car the next time we are up there.

 

Now that's a great gas cap.

 

I also shortened my column about 2" as I hated having the wheel so close up to my chest.
That was a great improvement for me and my seat position.

 

Thanks for the replies! I am very interested in the electric power steering… when we get to that point….

 

12 volt I believe....

LynnW

 

We are having the same problems on a 1956 Ford Parklane Wagon....

LynnW

 

I will take some pictures of the column in the car and PM them to you.

I have a leftover column, in what I think is the same diameter tube, that I could donate a chunk to help you along.

 

I would like to have some pictures.... Thank You....

LynnW

 

That left over part is the turn signal cancel. It just clips on the bottom of the steering wheel. It can be a bit of a tight fit but that is what you want.

 

Great! Thanks!

 

we only had the chrome for the trunk emblem... So back to the 3D printer for an insert. This will go along nicely with the gas cap cover...



I will likely reprint this emblem at some point to clean it up a little, but for now, he is super happy with it!

I hope to have some time this week to ****on up all the wiring, Then we will be ready to do the Geo Metro power brake conversion, and hopefully get to drive it for the first time!

 

We got a lot done on Monday... The wiring is 99% done, and everything seems to work like it should with the exception of 1 bulb socket. We also installed an aftermarket 3 gauge set, and now we can see that the car is charging at 14 volts.





The gas cap cover and trunk badge turned out great too!




The next step is the brakes. I am going to get new wheel cylinders, brake hoses, shoes and hardware. I'll have the drums turned if need be.

Are steel braided brake lines that much better? Or is it all looks? We are adding power brakes, so if the stock style hoses aren't sufficient, ill get steel braided...

 

Do you guys think I should use steel braided brake lines, or are rubber lines fine with power brakes?

 

Rubber lines are fine, so long as they are fresh, and from a good vendor.