Falcon Strip Party Update – What not to do…
1963 Ford Falcon Build Update
In case you missed the last story, I’m rebuilding my 1963 Falcon Wagon. Originally, I just planned to put some paint on it and re-do the interior, but after inviting a bunch of friends over (here’s the story), my wagon’s now a stripped hulk sitting in my garage. Borderline panicking but not quitting, I’ve still got great friends helping out. We’re making progress. It’d be easier to get out to the garage if it wasn’t 112 today!
First off, I have to mention the tireless help I’ve been getting from my friend Ken Ford. (perfect name for the project, right?) Ken’s a body guy and was looking for a reason to get dirty on a project. He’s got a Harley at home now has built several VW’s in the past, including a few vans, so he knows how to get body panels looking good.
It’s a good thing too! We’ve been moving around the car looking for disasters. We really only found 1. The previous owner decided to fill the cowl vent. I guess it looks a little smoother, but I’d leave it. (too late now!) I wouldn’t mind putting it back either cause it might be easier when you see the mess he left. 
We knew there was a problem there because the bondo had cracked. When we got to work cleaning it out, this is what we found. It’s hard to see from this picture, but there was about 1/2 inch of bondo covering this patch panel. He didn’t finish-weld the patch, so I think some moisture got underneath it and cause the cracking. This is gonna require some minor surgery to repair. I think it might actually be easier to find a new cowl and put it in. What do you think?
While Ken’s been hitting the outside, I’m inside cleaning the floorpan. It looked pretty nasty at first, especially in the pics. Really, it’s not that bad. Everything all rusty colored, but there was only one small spot of cancer rust. I’ll write about how I handle that in another blog. Here’s the before, during and finished pics of the floorpan. I’m going to use POR-15 to seal the floor up, then insulate the hell out of it. I removed about 20lbs of muck and filth from the car. Ever wonder where that “old car” smell comes from? I can tell you! I’ve also included a pic of the rear floor. I hit this thing HARD with a wire wheel and it still looks pretty nasty. I’ll cover it with carpet anyway, so it’ll get more POR-15.
So here’s the progress on the rest of the car. We had to strip off all of the old black primer. The previous owner used some kind of oil or something, (I thought it was Armor Al) to keep the primer looking somewhat shiny. Whatever you do, don’t do that. Ken was using up DA sanding paper like crazy with that crap loading up. The cars all spotty, but when Ken throws down some primer, it looks good. I hit the front fenders with some paint stripper and then with a wire wheel to get all the black off. It’ll look worse before it starts to look better.
I also included a shot of the first of many paint supplies I’ll need. The guys at ARS, Finishmaster hooked me up a little and are going to try and help get PPG to sponsor the build. Brandon at ARS didn’t mind waiting a bit since I came right from work, even on a Friday evening. Its nice to work with good people. Rather then buy this and that from a swap or an auto parts chain, I’m buying all quality supplies. With all the work we’re putting in, I want this to be nice.
Brandon also started helping with colors. That’s gonna be a tough choice. I know it’ll be blue cause that’s what my kids want. I know the car was originally Heritage Burgundy. It’s a cool color, but it ain’t blue. A friend said that Ford offered a light blue similar to what I’m looking for in 1963. Brandon said to look at www.AutoColorLibrary.com to find the color. Glacier Blue or Peacock Blue might be cool.
Every story I’ve written about this build can be found here: 1963 Ford Falcon Wagon Build
That’s it for now! Thanks to my current sponsors:
- Heat and sound insulation from Auto Insulation
- A great new steering wheel, a stock one from Cesar at Vintique Inc.
- Doug Jerger and Squeeg’s Kustoms for the Epoxy Primer Filler
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I think I’d just replace the cowl, Craig.
Just one guys opinion.
Looks like the project is coming along.
That POR 15 is good stuff. Works well.
Just don’t get any on you or your clothes,
cuz it ain’t comin’ off!
Keep us updated.
welcome to the world of having a wagon hulk in your garage. me likee :)
The fun has only begun!! It’s coming along nicely, and is a very solid car to begin with… I think the minor issues (like the cowl vent “fill” and the tiny holes) are a fair price to pay for such a good starting point.
We’ll dial in the right blue/blues, and nail something the kids will love, and that will make the car a stand-out everywhere you drive it!
Keep it up!! 112-degrees or not!
Hey Nelz, that’s a good point!! Actually, that’s like 1320 good points!
If only….
Don’t forget, there’s a sponsorship opportunity for a rendering (to help get MORE sponsors!) and for the radical pinstriping this bad bird’s gonna get. Either of you guys know anyone with those specialized skills?
pikesan
Too bad you don’t know anybody who could do a rendering of your car so you could get an idea of how it will look when it’s done… maybe there’s somebody on here that knows how to do them..
One thing I didn’t like about my 61 was the lousy fuse box and it’s location. If you have the same lousy location off the headlight switch, I’d make a separate headlight switch and put in a modern fusebox in an easier location.
That’s a cool project. I recently found a ’63 Falcon wagon in Garland Texas that I’m thinking about buying, but it’s got some bad rust on the body and some rusted out freeze plugs on the back of the heads on the 260 v8. The guy wants a grand for it, but I’m not sure it’s worth it.
Anyway, your project looks cool.
I thought I would reply to your message on my wagon. Thanks for the nice comments on my car..I have done a little more since that video/photo. I made a custom dash to match the original but a little bigger to except 6 real gauges and I also installed custom made stainless export brace and monte carlo bar along with a few other mods.. it’s a work in progress. always doing something to it when I’m not working on my other car a 1951 Ford Victoria street rod..
Looks nice. Love the gas door, what is that from?
To sib. I would grab a wagon at $1000. Can’t find anything decent here in Ontario Canada under $4000.
I am going to see a nice 62 on the weekend, 3 owner low milage.
Doug
Hi Doug,
The fuel door is the original skin of the car, I believe, with the hinge welded back on. It doesn’t fit very well so it’ll need some work to be finished.
Sorry to hear you’re having trouble finding a decent car. There was a 64 or 65 2 door wagon for sale here in town for $1500. They come up every now and then, but getting it to Ontario would be tough. Take care!