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Projects 1962 Falcon hot rod

Discussion in 'The Hokey Ass Message Board' started by Phipplet, Dec 5, 2020.

  1. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Today I installed the front disc brakes. This is probably the easiest aftermarket installation of disc brakes I have ever done. The quality of the product, the attention to detail and the exacting specs were awesome. They created one fine product. Enjoy..

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    Last edited: Mar 2, 2021
    31Apickup and loudbang like this.
  2. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Today I put the steelies back on the Falcon! It is very difficult to put a suspension on without the weight of the engine. Somehow I managed. Now I have the problem of installing the engine brace that attaches where the engine mounts go. Without the weight of the engine, the edges of the lower control arms stick out just enough to prevent the engine brace from slipping down. Any suggestions? I'm hessitant about putting lots of weight on the front of the Falcon.

    IMG_20210303_171029236.jpg IMG_20210303_171034450.jpg
     
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  3. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Okay, I'm always learning something new. I discovered the aftermarket engine brace does not go "between" the engine mounts, it goes behind them. Thus the lower control arms can move freely. Next I discovered, after talking with a friend, the original engine mounts are offset! I learn something new everyday.
    IMG_20210305_133259229.jpg IMG_20210305_141726492.jpg IMG_20210305_133312198.jpg
     
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  4. deathrowdave
    Joined: May 27, 2014
    Posts: 2,749

    deathrowdave
    ALLIANCE MEMBER
    from NKy

    I think your calipers are reversed side to side , bleeder screw needs to be at the top of the caliper , to correctly bleed the system .
     
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  5. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

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  6. pgj
    Joined: Dec 24, 2010
    Posts: 138

    pgj
    Member
    from aurora co.

  7. caper
    Joined: Jun 12, 2009
    Posts: 36

    caper
    Member
    from Cape Cod

    Plus 1 - bleeders must be on top.
     
    loudbang likes this.
  8. Looks to me like the caliper brackets are swapped side-to-side. All the conversions I've seen or done puts the calipers on the trailing side of the spindle, not the leading side. That would also fix the bleeder orientation. That also allows better cooling to the rotors.
     
    loudbang likes this.
  9. One other thing you should probably do is reinforce the shock towers where the upper control arms attach. Ford built two different bodies for the early Falcons; a 6-cylinder version and in '63 with the addition of the optional V8 a V8 version. They increased the metal gauge in the framerails, rockers, and shock towers and added additional bracing in the shock towers as well as torque boxes tying the framerails and rockers together to handle the additional weight/power of the V8.

    I would consider reinforcing at the shock towers as mandatory. On the V8 cars the metal is about 3 times as thick there to prevent cracking around the bolt holes. I have seen these crack and tear out, even on the V8 cars under extreme use. Adding the under-motor crossmember and shock tower brace will help prevent cracking in other places. Hopefully you've added subframe connectors as that really helps with body flex. Adding torque boxes will also help.

    About 20 years ago I did more-or-less the same thing to a '64 Comet. One thing that was interesting was Mercury only used the V8 body in '64/65, regardless of motor, citing better NVH (noise, vibration and harshness). Now when I talked to Global West at the time, they recommended (for street use) NOT using metal or urethane bushings on the strut rods or lower control arms as the shock loads transmitted by those could cause issues. Public streets present more hazards than race tracks was their explanation. The car handled like it was on rails, but ride quality started to get a bit harsh.

    'Back in the day', Ford recommended seal-welding most of the seams to improve structural integrity if going road-racing (this was done on the factory Trans-Am cars), and this was on the V8 body shells.

    Do monitor the upper a-arm attachment points for cracking because if this tears out at speed it can be catastrophic....
     
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  10. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    I have the shock tower supports. Thanks for the info!
     
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  11. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    This is why I enjoy forums. The instruction have the calipers foward, but I think I'm going to take your advice and flip them. Yes the bleed off valves have to be up. Didn't some Ford trucks have the caliper on the front of the rotors? Do you guys see any issues with flipping the calipers to the rear?Thanks again for the advice! Here's the instructions.
    IMG_20210307_151340674.jpg
     
    Last edited: Mar 7, 2021
  12. deathrowdave
    Joined: May 27, 2014
    Posts: 2,749

    deathrowdave
    ALLIANCE MEMBER
    from NKy

    If they are to be mounted forward , swap left to right and right to left . If the bleeder is not at the top of the caliper, you will never get your brakes to work correctly . I don’t know what it will take , swap brackets or only calipers , but bleeder not at the top , you’ll make up potty words , trying to get good medal travel on the brakes .
     
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  13. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    I emailed the manufacturer. He got back to me today! On a Sunday. I have everything correct, but the calipers are backwards. They are even marked Left / Right. DUH! The calipers can't go to the rear, because the spindle's steering arm would interfere. There ya go.

    IMG_20210307_165347347.jpg View attachment 4999601
     
  14. deathrowdave
    Joined: May 27, 2014
    Posts: 2,749

    deathrowdave
    ALLIANCE MEMBER
    from NKy

    Great ! You will be a happy camper now ! Great job , great build . I’m just trying to increase the fun factor for you as much as I can . Believe me when I tell you , I know to look for this because I learned the effects the hard way .
     
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  15. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Waiting on paint and a couple parts to arrive. So I decided to clean up, modify and paint my inner-fender shock tower covers. Whatcha think?

    IMG_20210308_164415473.jpg IMG_20210308_164339825.jpg
     
  16. caper
    Joined: Jun 12, 2009
    Posts: 36

    caper
    Member
    from Cape Cod

    Nice work - looking good !
     
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  17. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Just picked up a Ford 9" for cheap. 3.70 gear ratio, big bearing. Only catch, it's completely disassembled! Guess I'll be studying up on how to reassemble. Any pointers or tips are welcome and encouraged! Thanks

    IMG_20210315_093240409.jpg
     
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  18. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Got a chance to work on the Falcon today. Finished painting the engine compartment. I also installed the motor mounts and engine cross brace.

    IMG_20210324_171257878.jpg IMG_20210324_171615356.jpg
     
    loudbang likes this.
  19. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Found some NOS Falcon emblems locally on Craigslist for $25

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  20. Phoenix24
    Joined: Nov 21, 2019
    Posts: 147

    Phoenix24

    Daaang! I had to hunt down some open lettered ones, those are mint! Can't wait to see them on the car!

    Sent from my SM-G981V using The H.A.M.B. mobile app
     
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  21. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Well, I painted the engine and put the heads and intake on. I also pulled the rear-end and the 1980's Traction Bars! I also removed the gas tank. Discovered a lot of rust in the trunk. Does anyone know if they make trunk patch panels? Thanks

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    IMG_0105.jpg
     
    Last edited: Apr 14, 2021
    loudbang likes this.
  22. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    Getting the engine together. Looking for suggestions on spark plugs and slant edge valve covers.

    3C245002-EBA2-4D6F-81F7-10EA22A07349.jpeg 1C13EE84-26AE-481A-8552-F2328F728895.jpeg
     
  23. oldiron 440
    Joined: Dec 12, 2018
    Posts: 2,532

    oldiron 440
    Member

    Slant eadge valve covers?
     
  24. seb fontana
    Joined: Sep 1, 2005
    Posts: 7,210

    seb fontana
    Member
    from ct

    Looks like the heads have guide plates and rail rockers for the pushrod/rocker alignment? Shouldn't have both. I would do a quality set of roller rockers, adjustable guide plates; they will last forever.
     
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  25. oldiron 440
    Joined: Dec 12, 2018
    Posts: 2,532

    oldiron 440
    Member

    Proform makes those, I think Trickflow has a set for $130.
    Trickflow is a Summit brand.
     
    Last edited: Apr 23, 2021
    loudbang likes this.
  26. Malcolm
    Joined: Feb 9, 2006
    Posts: 7,789

    Malcolm
    ALLIANCE MEMBER
    from Nebraska

    Cool little Falcon project. I'm looking forward to following along. Nice work so far!
     
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  27. Phipplet
    Joined: Jun 12, 2020
    Posts: 56

    Phipplet

    I know it's been awhile since I've posted anything, just been busy. I'm still working on the Falcon. I recently took the forum's advice and installed roller rockers. I also recently purchased a 62 Falcon Squire Station Wagon. IMG_1563.jpg IMG_1566.jpg IMG_1379.jpg IMG_1492.jpg IMG_1402.JPG IMG_1533.jpg IMG_1529.jpg
     

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  28. loudbang
    Joined: Jul 23, 2013
    Posts: 39,681

    loudbang
    Member

    Thor1 likes this.
  29. Wow, that's a cool wagon. That's an interesting way to use a center console with a bench seat.
     
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