MrModelT Builds.....A Falcon?

Bigcheese327 · May 31, 2012

Following up on the e-mail I just sent you, you may find these pictures inspirational. I know I did:

I need to find a clearer view of that air-filter decal!

MrModelT · Apr 4, 2013

*UPDATE*
Some Progress....Hey, at least its somethin'

Progress has been slow since the return from Bonneville. We spent a great deal of much needed time doing plenty of repairs and reorganization on the shops, but are now getting back to the cars again.

After a good "stir" and clean out of the main building, we decided to shift some cars around to give us more room to work...the Falcon was one of these. She had been back in the far corner of the building since 2011 and it was just to hard to get anything done. I spent a Saturday a few weeks back getting the shell cleaned out and ready to move, as well as helping Troy and Chris get the front corner of the building cleaned out.

Then we pulled the Falcon out into the sun for the first time since June 2010.

Before getting it all set up in it's new location and up on blocks:

Over the last 2 weeks I have been working to get the rest of the front suspension system out and the body ready for stripping:


I am also at a crossroads. For a few years now I have wavered back and forth on switching engines: Sticking with my 200 6-cyl plan..or going to a 289. I love the 6, But have always wanted to build a nice 289.

I knowI know what you saying right now..How can you think of a 289 after all that planning?

The 200 6-cyl project will be a major project with plenty of unknownstoo many I fear. This motor would never be just a 6-cyl with some bolt on speed goodies and a hot camthis would be a major R&D project to redesign that motor in my image. It would take years of research, planning, design and re-design,etcthen testing it all to make sure it all works and performs like I want it to. How much time and money will it take me to get to that point? What if it doesnt work or perform like I want and I have to start all over?

I dont want to spend 15 years working on my Falcon and dont want to put tons of money into just the motormoney that could do the entire suspension and drive train. I feel I could build a hot 289 w/Paxton Supercharger for half the money I would spend building the 200.

The small 6-cyls can be built as a HP motorbut they do have their limits. I dont know if I will be able to get the HP I want without sacrificing its street-ability that I am shooting for as well. I fear that this motor will end up being a real high RPM screamer in the top endeven with the 5 speed. The 289 would give me all the power I need in all bands and be a great road car (for road trips) as well as a decent strip carand it would sound GREAT.

I also dont need to build something super exotic..something to outdo the T on the coolness scale..just need to build something I enjoy.

The rest of the plan will remain the same, but the engine will change to a Paxton Supercharged 289....

Thoughts?

MrModelT · Apr 6, 2013

Bump...

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i like cars & stuff · Apr 6, 2013

MrModelT said: ↑

*UPDATE*
Some Progress....Hey, at least its somethin'

The rest of the plan will remain the same, but the engine will change to a Paxton Supercharged 289....

Thoughts?

Click to expand...

Ok.

blyndgesser · Apr 6, 2013

If it were my car, I'd rather see the Six done right, with a CI aluminum head, a four-barrel and a T5. But of course, it's not. If I were going to do a 289, it would be hard to resist the temptation to put a set of four Webers on it.

MrModelT · Apr 6, 2013

blyndgesser said: ↑

If it were my car, I'd rather see the Six done right, with a CI aluminum head, a four-barrel and a T5. But of course, it's not. If I were going to do a 289, it would be hard to resist the temptation to put a set of four Webers on it.
Click to expand...

I agree...but I was staying away from the more common 4-bbl in favor of a custom made triple 2-bbl intake with a Paxton. Sadly, I think I would be into this 6 to far by the time I got it all designed, built and tested.

4 webers does sound awesome.....wonder if I could run just 2 with the Paxton?

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Bigcheese327 · Apr 7, 2013

You know my thoughts on the matter. I want to see that birdie on the road!

MrModelT · Apr 7, 2013

Bigcheese327 said: ↑

You know my thoughts on the matter. I want to see that birdie on the road!
Click to expand...

I certainly do. You have always been my "Moral Compass" on this build. I just thought it was time I updated everyone else on what I'm thinking.

You are of course always welcome to offer your wisdom anytime

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Bigcheese327 · Apr 7, 2013

Speaking of sixes with aluminum heads; did you see my new engine?

Bigcheese327 · Apr 7, 2013

Speaking of '65s with Paxtons. Check this.

MrModelT · Apr 12, 2013

Bigcheese327 said: ↑

Speaking of sixes with aluminum heads; did you see my new engine?
Click to expand...

Bigcheese327 said: ↑

Speaking of '65s with Paxtons. Check this.
Click to expand...

That 250 looks good in the back of your car coming home....but will look way better between the shock towers of the '62

Thanks for posting that Rancho witht the paxton....kinda what I'm going for.

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MrModelT · May 20, 2013

*UPDATE*
Finally...some decent progress!

I finally got a chance to make some real progress on the old Falcon this weekend.

First thing Troy and I did was take the Falcon off of the wobbly jack stand carts and built a nice sturdy rolling wooden frame to hold the body that I can easily move in and out of the shop with ease by myself...

I always knew there was rust in the car since I bought it in 2001, but I didn't know exactly how bad it was until I really started digging into it.

Falcons are notorious for rot issues and leaks in the cowl area (under the fresh air vent) and around the under dash air and heater vents. The best method for correcting this is to drill or cut all the spot welds holding the cowl piece in place and remove it giving access to the inside of the cowl.

I was always hesitant at first to cut on the car that much...but after searching that repair I feel confident that it needs to be done when I have the car apart and that I can do it.

Yesterday I made the first steps in removing the cowl by removing the fenderwell-to-cowl support using my new 3/8" rotary spot weld cutter...

I also found more rust in the fender well then I had assumed there was....here is what I found with the wire wheel...

Troy also gave me a hand by stripping the under coating off the fender well in prep for blasting...

Still have some more work to do yet before we blast....so stay tuned for more

Veach · May 20, 2013

Looks like you have some Awesome Rides and a Awesome Shop good luck with the Build

Bigcheese327 · May 21, 2013

It's so nice to see this kind of attention lavished on a Falcon with stock suspension. Seems like most guys get to this point and say "I decided it would be just as easy to do a Mustang II / straight axle."

MrModelT · May 21, 2013

Bigcheese327 said: ↑

It's so nice to see this kind of attention lavished on a Falcon with stock suspension. Seems like most guys get to this point and say "I decided it would be just as easy to do a Mustang II / straight axle."
Click to expand...

Thanks kindly Dave....and you haven't seen anything yet . My level of care and detail will know no bounds.

I really couldn't fathom a Mustang II in a car like this...it's just not right.

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i like cars & stuff · May 22, 2013

Subbed this thread.

MrModelT · May 22, 2013

*UPDATE*
"Open Sesame"....

In my last update, my friend and shopmate Troy and I were working on removing the cowl to assess the rot damage to the inner cowl area....something Falcons are notorious for. We had started by removing the cowl-to-fender well braces.

Last night we made a big leap in successfully removing the cowl.

Each of us with drills in hand went after the 150+ spot welds that hold the cowl panel in place...

There were so many....I think the old Ford Spot weld guy was looking for a promotion or a raise

After cutting a few welds along the front edge of the cowl....and cutting a few more missed spot welds..

...The cowl panel came off...and I was both surprised and pleased with what we found.

This particular car has bad rust is odd places.....but no damage at all in the places it should. Save for the large mouse nest on the drivers side....everything was in remarkable shape!

The cowl deck has almost NO rot at all...just 2 small pin holes that will be easily repaired....

...The drivers side air vent collar is oddly well preserved.

The passenger side collar is rotted, but that was know back when I first bought the car in 2001. Dad and I repaired it with a temporary repair that lasted the last 12 years...

The cowl cover panel is also really well preserved....for not having much primer or paint on the inside...

Now we are almost ready to blast, prime and get to body repairs!

Stay tuned for more!

And for those that have commented on the shop....our little shop is a cool place. It belongs to a good friend Chris (Powerwagonmanic) who runs a "DIY" restoration shop from here. There are three buildings with space for renters, a full paint shop, machine shop, storage etc. It is the collective 50 year legacy of Chris's Dad, Bill, and Grandfather.......all of it built primarily as a family and friends hobby hangout.

And there is plenty of great early iron to play with in the Becker's family collection. I service and maintain all these beasts

tbone1 · May 25, 2013

This is cool. I am in the middle of a 64 four door rebuild. I will be watching closely.

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MrModelT · May 25, 2013

tbone1 said: ↑

This is cool. I am in the middle of a 64 four door rebuild. I will be watching closely.

Posted using the Full Custom H.A.M.B. App!
Click to expand...

Thanks! Nice to see someone else doing a 4-door. What is your build plan for your '64?

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Kume · May 26, 2013

What is that vehicle in the far corner of the shed - looks a bit like an international?

MrModelT · May 26, 2013

Kume said: ↑

What is that vehicle in the far corner of the shed - looks a bit like an international?
Click to expand...

Good eye its an original, unrestored 1906 Holsman Model 10

Been at the shop since 1965....is a boxer style 2 cyl air coold engine, chain drive jack shaft and rope drive to the rear wheels.

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Kume · May 26, 2013

What an absolute treasure.

MrModelT · May 28, 2013

It is Kume and the most fun I could ever have whenever I get behind the tiller. I can't wait to get the engine back with new rings and rod bearings so we can get it back rolling again!

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JEM · May 28, 2013

Not a lot of source info but a couple early Falcons running USRRC visible in the background:

http://www.lotuscortinainfo.com/?page_id=1938

(think I've decided my $250 GT shell is gonna end up whatever red the AMR cars were...the Team Lotus white-with-green-flash has become a bit of a cliche)

JEM · May 28, 2013

MrModelT said: ↑

Each of us with drills in hand went after the 150+ spot welds that hold the cowl panel in place...
Click to expand...

As with many tools, the difference between a good spotweld cutter and a cheap one is about two days of labor...

...but even with a good one you'd better have spares on hand.

MrModelT · May 28, 2013

JEM said: ↑

[/LEFT]
[/CENTER]

As with many tools, the difference between a good spotweld cutter and a cheap one is about two days of labor...

...but even with a good one you'd better have spares on hand.
Click to expand...

Very true...and it was because of that line of thinking I bought 2, double sides spot weld cutters from Harbor Freight....thinking I would go through them all before the job was done.

To my surprise......I used only one of the cutters....and didn't even reverse the cutting head. The teeth on side one were still just as sharp after 150+ holes as when I started.

No bad...

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tbone1 · May 28, 2013

ModelT, my 64 is my first build, so I am doing something most would consider typical. 302 with 1966 289 heads edelbrock 289 performer intake with an edelbrock 600 cfm carb. T-5 trans with hopefully a nine inch with a tru trac and 3:50 ratio. I'm still looking for the rear end. As with most of us, I'm on a buget and curry rear end i want is out of range. Suspension will stay mostly stock but i am switching to the 65 mustang V8 steering setup.

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Bigcheese327 · May 28, 2013

tbone1 said: ↑

ModelT, my 64 is my first build, so I am doing something most would consider typical. 302 with 1966 289 heads edelbrock 289 performer intake with an edelbrock 600 cfm carb. T-5 trans with hopefully a nine inch with a tru trac and 3:50 ratio. I'm still looking for the rear end. As with most of us, I'm on a buget and curry rear end i want is out of range. Suspension will stay mostly stock but i am switching to the 65 mustang V8 steering setup.

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Click to expand...

Sounds like a very pleasant driver. Any reason you need a 9"? Sounds like you may already have the gears? Otherwise a Maverick 8" or Explorer 8.8" with the long side shortened might be more budget friendly.

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tbone1 · May 28, 2013

Bigcheese, I may go with the 8 or 8.8 if i come across one, but I may go with something like a procharger down the road and i don't want to have to have upgrade the rear end if i do. It's all subject to change depending on my mood.

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MrModelT · Jan 20, 2014

*UPDATE*
Finally....ready to blast

It has been far too long since I posted an update, but other projects took priority for a while. Now the schedule is clear and Falcon work will continue...as will more regular updates.

For the last few weeks we have been working to get all of the 50 year old, dealer applied undercoating from the underside of the chassis in preparation for sand blasting. With needle scalars in hand....we went after the undercoating and it just flaked off with out much fight. Underneath....we were really surprised at how WELL PRESERVED the underside of the body was.

There is rust, don't get me wrong and I certainly have some patching to do....but the underside is largely clean and rust free. Even the torque boxes ahead of the rear springs, which are usually one of the first places to rust, are clean and solid. As a friend on Instagram put it..."Probably the first case in which dealer-installed undercoating actually worked!"

Here is a look at the fun:

More to come...

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*MrModelT Builds.....A Falcon?*

Bigcheese327 Member from Bennington, VT

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i like cars & stuff Member from Aotearoa

blyndgesser Member from Georgia

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MrModelT Builds.....A Falcon?

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