BUILD THREAD For 1964 Falcon Sprint to Monte Carlo Rallye FIA spec'

[Paul B]

Thanks Mike,
You are right, Its possible to buy some aftermarket part that "will do". But I think, (only in my opinion) we are in a time now where these historic cars actually need to have a correct restoration, weather in fact if its a real car with history or if its a recreation of a historic machine.
I really have an appreciation of the cars that have retained all of the period character. For me with this build as a recreation of the Graham Hill car # 201 from the 1964 Monte Carlo Rallye, to try and get all of the factors of the car in correct detail and colours and in turn it will hopefully portray to people viewing the car just how it was in 1964.

Here is a pic of the completed restored manual transmission floor hump panel.
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[Oldfart]

Another Wow from me. As they were is the way I like them too.

[kiwi285]

Here is a pic of the completed restored manual transmission floor hump panel.
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Real craftsmanship Paul and an indication of perhaps how others couls approach their restorations.

[Paul B]

Thanks Rhys & Mike, I think there are a few very nice race car builds currently underway, 1 is Paul McCarthy's Broadspeed Escort, a fantastic build and all credit to Paul Mc' he is making such a nice job on his car, I am sure you all will be impressed.
Cheers
P

[Spgeti]

We currently have 4 Mk1 Escorts being built to FIA Appendix K all powered by 2Litre BDG’s.
They are all fantastic builds and will add to HSC’s grid along with Paul’s Falcon.

[Paul B]

And you watch those Escorts go, they will be very quick. Very keen to see them all on the track!

[ERC]

I really do admire this sort of talent. As one who only ever had 1 year of metalwork at senior school in the third year (the school was brand new and the previous two years, also at a brand new school, the metalwork shop hadn't been finished - post war boom baby problems), my metalwork ability is zilch. Dad was very good at woodwork, but he too had zero experience with metal.

Methinks that the degree of talent or depth of pocket often has an effect on an attitude to period correctness.

Great stuff Paul and as one who can't even cut a piece of metal, it is great to see what has gone into a build.

[Paul B]

Thanks Ray,
I am just one of those car guys, the same as anyone else. But... a bit (a lot) of a detail person and things that are not done right on my builds annoy me enough to motivate me to get it done correctly. I really enjoy working with steel and aluminum, funnily enough I dislike working with wood or on houses... probably because houses don't have wheels!
Cheers
P

[Paul B]

Another great view of St Mary’s Trophy Race 1 at Goodwood Revival 2015
Great battle between The Alfa, Cortinas and Fairlane


https://www.youtube.com/watch?v=o25ats_KXRk

The 427 Fairlane Holman Moody Sport coupe (incorrectly called a Thunderbolt by the commentators)

[Paul B]

And heres one inside a 427 Galaxie

https://www.youtube.com/watch?v=07e7rQaKKWQ

[Andrew Metford]

Did you say understeer?

[Paul B]

Did you say understeer?

Not sure what you mean Andrew?
The two video clips prior to this, the cars had a lot of oversteer going on, which is fun to watch.

[Andrew Metford]

Not sure what you mean Andrew?
The two video clips prior to this, the cars had a lot of oversteer going on, which is fun to watch.

On the in-car video, he seems to be turning the wheel a lot to get it around the corners. Looks to me like lots of understeer, but maybe it's got a low ratio steering rack ( i.e. not a quick rack )?

[Spgeti]

They are under shod and the tyres are bias treaded hence why they slide around. Basically the same tyres as we use in HMC but narrower.

Regards
Bruce

[Paul B]

Yes, Spgeti is right.
Also these types cars have a worm & sector shaft steering box, they are sometimes notorious for center play at the steering wheel. Which means sometimes extra turning left or right, past center to take up a bit of the play. (not uncommon for 1/16 turn left or right to take up play in a incorrectly adjusted box)
Definitely not ideal, its possible to adjust this out providing there is not excessive wear on the worm block or sector shaft.
Also the steering could likely be 17:1 which also would not help.
Great drive though! on post #260
Cheers

[Oldfart]

They are under shod and the tyres are bias treaded hence why they slide around. Basically the same tyres as we use in HMC but narrower.

Regards
Bruce

There are pretty strict rules to get the cars appearing as they did in their time. Of course the engine department is nothing like it. Looks the same, but the extra horsepower..... (My opinion and I am allowed it :) )

[Spgeti]

There are pretty strict rules to get the cars appearing as they did in their time. Of course the engine department is nothing like it. Looks the same, but the extra horsepower..... (My opinion and I am allowed it :) )

You are correct Rhys and you are allowed as well....

[Paul B]

Agree! opinions are good.
My goal is to build inside and out, exactly the same as the 1964 Graham Hill #201 car. I have been collecting parts according to the historic photos I have been working off. have been collecting a lot of old parts and restoring them to achieve this.
I want to be able to open the hood and there it is the same as 1964.
Also not planning to build an engine with extra HP, I will be building an engine based exactly on what was built by Holman & Moody. I may add some stronger conrods to preserve the engine as the K series 289 HP engine blocks/engines are extremely rare now and expensive, if you could get one with enough meat in the bores to use.
It is all coming into place as I now have 95% of all the parts to complete the car.
Update:
I have been preparing the car for paint primer for the last 2 months and about 85% through now. The fiberglass parts again have been slowing me down as they require so much work to prepare them so the panels don't look like the pacific ocean when you look down the side of the car.

[Oldfart]

Maybe the panels were like the Pacific Ocean in the day Paul :) In that area you are "allowed" to improve.

[Paul B]

Maybe the panels were like the Pacific Ocean in the day Paul :) In that area you are "allowed" to improve.

Yes agree Rhys. I do not think the 1964 original fiberglass panels would have been perfect by any means, so I am leaving some minor deflection of the new fiber panels in this build. in an attempt to keep it real.
The big problem with fiber panels is where, for example, a boot lid is made in 2 pieces and the outer skin is glassed to the entire inner frame and over time some shrinkage occurs at the bonding points, which causes a lot of hollows and high spots in the outer skin. This can take months to show after the panels are made. I will be looking to remove most of this (pacific ocean) only.

[Oldfart]

Dead right Paul. It was an area we worked hard to prevent when I worked in the industry. Not hard to eliminate at moulding stage if you just use "correct" techniques, but a real pain later on. I admire your efforts.
It might pay to leave them for a while before painting just in case the tide comes back in.

[Paul B]

Thanks Rhys, The panels were made about 12 months ago and I have been leaving them cure in my hot garage and in the sun to give them a good cooking. I am expecting further movement in the panels once the paint solvent hits it.
These panels were manufactured a little too light, in my opinion, mainly made for drag racing, but I have put a lot more woven structural glass into the undersides of all the panels to get them to where they need to be, I am very happy with where they all are now but it has cost me so much time it would have been quicker to make my own plugs and panels.
You live and learn. It has been a good experience and I now have a fairly good understanding (and appreciation) of Fiberglass.

[khyndart in CA]

Hey Paul,
You could put on some logging truck mudflaps and join the rally scene !


https://www.youtube.com/watch?v=QNrAl0DdeIQ&t=325s

Ken H

[Paul B]

Looks like a ton of fun Ken!
The Swedes just love sideways motorsport and they are very good at it.
Cheers

[Paul B]

Time for an update on the Falcon Rally Sprint. Following on from post #220, I have done the final panel fit & gap of all of the fiberglass panels and very happy with the fit.... now. I have been working on paint primer preparation for the last 2 months and the whole car is all straight now also the fiber panels are all epoxy etch primed
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I have some small finishing to do and seam sealing then its gets an all over 240 sand in for pre-paint primer and then more sanding.
Bodywork is always the longest part of the build.

[Oldfart]

Superb work Paul, what a build, please don't bend it!

[Steve Holmes]

That is looking amazing Paul! Great work.

[Paul B]

Thanks Steve & Rhys,
Certainly not going to bend it after the time and energy shoveled into it. I will probably drive like a Nana for a while! or at least until I get the feel of the car. I am very keen to drive it.
I just love analog cars, no computers, no beeps & dings etc and I can tune it without a computer!
Cheers

[Paul B]

Paint preparation is all about detail, patience and perseverance -
and to coin a phrase from Forest Gump:
"And that's all I've got to say about that"

This week I have been working on sanding the floors & epoxy etch priming. I now have no fingerprints left.
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On most of the weld repairs I have left the reverse side very smooth but a weld line just visible as you can see in the top left side of this pic. There is a triangle shape repair to the floor just below the roll cage floor plate. This is part of the time line character of the car.
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Rear seat floor area
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Last week I finished the rear of the car which completes the outside, ready for 240grit sand then primer
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When preparing a car shell that has been totally paint stripped there are many more tasks to complete and more surfaces to prepare coupled with the all important seam sealing.
Its very close now.

[khyndart in CA]

So Paul,
How many of your mates can you fit in the boot/trunk to sneak into the race track ?
(such as in the old days at Pukekohe and Bay Park by someone I know ! )
(No wonder NZ motor racing lost money !)

KJH

[Oldfart]

So Paul,
How many of your mates can you fit in the boot/trunk to sneak into the race track ?
(such as in the old days at Pukekohe and Bay Park by someone I know ! )
(No wonder NZ motor racing lost money !)

KJH

And the Matamata Hotsprings! Yes Baypark, and Puke. A Standard 8 was good for that as there was no bootlid for the security guys to open and see :)

[Spgeti]

Great work Paul. Looking really good.

Yes we use to try hiding in the boot to get into the Drags at Meremere....never worked !

[Paul B]

Thanks Guys,
I used to own a 1960 Ford Fairlane 4 door (AKA the Mothership) I am pretty sure we fit 3 in the trunk of that one time.

Old fart have you been sprung, by Ken?

Cheers

[Steve Holmes]

Paint preparation is all about detail, patience and perseverance -
and to coin a phrase from Forest Gump:
"And that's all I've got to say about that"

This week I have been working on sanding the floors & epoxy etch priming. I now have no fingerprints left.
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On most of the weld repairs I have left the reverse side very smooth but a weld line just visible as you can see in the top left side of this pic. There is a triangle shape repair to the floor just below the roll cage floor plate. This is part of the time line character of the car.
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Rear seat floor area
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Last week I finished the rear of the car which completes the outside, ready for primer
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When preparing a car shell that has been totally paint stripped there are many more tasks to complete and more surfaces to prepare coupled with the all important seam sealing.
Its very close now.

Wow, great work Paul! This thing is just looking so good! And you're getting close now!

[Grant Ellwood]

Great work Paul. Looking really good.

Yes we use to try hiding in the boot to get into the Drags at Meremere....never worked !

Last century a bunch of us got in to Puke several times beneath a tarp on Bryan Faloon's trailer.

[Paul B]

Thanks Steve, I only have seam sealing to do now. The painter is coming on Thursday to have a look at the car. It has been a mammoth task integrating the fiberglass panels but most rewarding now to see it done and functional.
Cheers

Also,
Nice to also see everyone fessing up to days gone by from last century ^^

[Oldfart]

We were poor then, and you think licking tar from t'road was bad, we had it tough....We got evicted from our hole in t'road :)

[Paul B]

Ahhh the good old days!

Here is a great link to a web site about Graham Hill, a great story and some great pictures. The site looks like its South American, so as you scroll down select english language, the translations are not the best but worth a look.
http://www.pilotos-muertos.com/2017/Hill%20Graham.html

[Paul B]

I took a break from sanding and finished engineering the gearbox cross-member. Holman Moody made a reinforced cross-member for these cars. The factory OEM cross-member is somewhat flimsy and only has 1 bolt holding the entire gearbox mount in.
This is a pic of the OEM cross-member (the leaf spring on this is for a 6cyl and auto models)
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So the reinforcing was 2 pronged:
1. reinforce the cross-member with 2 x 3mm steel plates which support the chassis mount points and welded in 2 x 3mm cross plates to the 2 new chassis mounts to support the actual rubber mount point, which is then bolted to the new structure.
2. So I needed to look at the single bolt, so I fabricated a 2mm steel plate which captures the gearbox mount spring, should the bolt fail, the new capture plate will support the gearbox so as to overt a disaster on the track.
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It looks relatively simple but it was quite a bit of engineering to finish correctly. (The leaf spring on my part is for the 4 speed models only)

[khyndart in CA]

Paul,
You continue to amaze. That is beautiful work my friend.

Ken.

[Paul B]

Thanks very much Ken.
Its all coming together nicely, hopefully it will be in the paint shop in about 1-2 weeks (For Primer) depending on how busy the painter is.
Wimbledon white is the colour for the outside.
Cheers

[Paul B]

I have been finishing the car for paint but in between I have designed the front and rear tow hooks and had them water jet cut from my design, finished and painted, Its 9mm medium tensile steel

Here is a pic of the water cut job as I got it back
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And here is a pic' of the finished product, deburred & all prettied up
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[Paul B]

I have finished the seam sealing, quite a big job and very messy. I followed the original workshop manual for this job plus remembered many spots that were not in the manual such as the roof drip rail and the inner, lower rear quarter below the rear quarter window etc.

The original 1960s seam sealer hardens after 50 years and cracks. This was all removed when the car was dip stripped
The modern seam sealer is very strong and durable stuff, it also has a level of flexibility and does not split or crack, and looks exactly the same as the original stuff.
When applied to a correctly to a prepared surface, it not only seals all the spot weld construction points/seams but it also adds a very strong bracing factor which supports the spot welds and seams.

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Once the fire wall and inner fenders are painted semi gloss black it will all blend in and hardly be noticeable
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The underneath of the floor was originally painted a Red oxide primer and will be repainted the same colour again
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The A pillars will be finished in white paint but are predominantly covered by Stainless bright trim
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I just some small repairs and touch ups to finish prior to primer.

[khyndart in CA]

Paul,
Bloody marvelous workmanship as usual.
So when are you going to move the steering wheel over or are you going to work for the Post Office and deliver mail ?
If you run out of things to do I have some projects here that need to be done properly and not hacked by someone my wife knows well !
I will also provide free transportation to Sonoma or Laguna Seca if we plan it accordingly.
Seriously, you do outstanding work and may it all come together easily for you from here.
Cheers,
Ken H

[kiwi285]

Beautiful work Paul - a really great job. This is one car that everyone will want to examine when it hits the track.

[Paul B]

Thanks Ken & Mike,
The steering wheel will for sure stay on the left side. we would love to come over to your part of the world Ken at some point. But for now I will continue finishing this beast off. Will stay in touch.
Mike, That will be the nervous thing ... when everyone examines the car! No pressure to get it done right!
Cheers to all.
P

[Paul B]

I replaced the hinge pins on the drivers door of the car, after 50+ years of door opening and closing the hinge pins and bushes wear out.
You will see the door will sag at the opposite end of the hinges, once it is opened, it is not uncommon for the door to drop 3mm to 6mm due to the wear. This makes the door hard to close as it does not line up correctly with the door striker plate. (this usually results in a "slam" to get it to close). The other issue is when the worn door is closed against the striker plate it will move up and down while driving, Not an ideal situation. I think this possibly may contribute to doors popping open in a collision.
So a worth while job to do
Most of the older Fords all have the same types of hinge pins and flange bushings.

This is a pic of the kit with the OEM hinge pin (rusty) on the side. There is 1 pin and 2 bushes required per hinge. The pin supplied needs to be cut to size and the end beveled/chamfered to match the OEM
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First job to do is mark the top of both parts of the hinge. Only do 1 hinge at a time so not to mix up parts
Next, using the cut piece of pin or old pin, use this to press out the old pin, and then drive it out with a punch
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Then you need to press out the old Bushes. First, knock the flange off 1 of the bushes (they are nickle copper) so it is fairly easy with a punch and hammer. then press out both bushes from the end the flange has been removed
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Then lightly de-burr the pin & bushing flange surfaces on the hinge (using a light file or emery paper) clean all the hinge pin parts and surfaces. then moderately tap the new flange bushes into place using a flat hammer being careful not to bruise it.
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Then cut and chamfer the new pin, clean it and grease it and the newly fitted flanges, then press it in place to the new assembly.
Job done
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[Paul B]

Back in the early 60s racing and NASCAR were really going ahead. Ford were racing the big heavy full sized fords all race prepped by Holman Moody. The 1960 Ford Starliner was really the first of the many Ford fastback styled cars. They were a very different design during that time, particularly in the rear wings. They were not every ones "cup of tea" but I think they are super cool, unique and different.
This clip is really an updated road car but will give you a bit of an idea on how they looked in the day.
The engine is a lowish output 390ci, but the 1960 cars were originally raced with 352ci and in 1961 a hot 390ci with 3 x 2 barrel carbs.


https://www.youtube.com/watch?v=RHGV8-wMTsQ

[Bruce302]

That is a very cool car, great period sound too. (interesting Nor Cal scenery)
I hope yours is driven like that.

[Paul B]

Maybe Bruce, I always like to hear a couple of thousand more revs to put a smile on my dial.
But they are a very cool machines.
Interesting, in 1962 there was no fastback roof (but a 406ci big block) for the full sized Fords and then came the very cool 1963 Galaxie Fast back roof and the big 427. then all the good fun happened from there.

[Paul B]

Maybe the panels were like the Pacific Ocean in the day Paul :) In that area you are "allowed" to improve.

Rhys, I was researching an old Motorsport Magazine article from 1964 that very interestingly it covered a road test on a 1964 Monte Carlo Rallye Falcon and they stated in that article that the "fiberglass panels were wafer thin" so you are right they would have looked like the pacific ocean when looking down the side of a painted fiber panel. I have left some of that type of deflection in my build (it is fairly marginal though).
They also commented on how surprisingly well the American Falcon handled and how relatively light the manual steering was.

[bill hollingsworth]

Group 2 footage at Brands Hatch.


https://www.youtube.com/watch?v=8Dxg_AT35GA&feature=youtu.be

[Paul B]

Great footage Bill!
Thanks for posting.
Cheers

[Steve Holmes]

Wow, fantastic video! Thanks for posting Bill. I think it might be Group 5 though, as opposed to Group 2. The BSCC used Group 5 from 1966 - 1969. Group 5 allowed more freedom than Group 2. Group 5 was used in New Zealand from 1968 to circa 1972. Group 2 was used during the 1966 and 1967 seasons, introduced by MANZ alongside the Allcomers, as they wanted to get the cars back closer to showroom stock.

[bill hollingsworth]

Here is some colour footage of the Group 5 Falcons at Brands Hatch in 1967.


https://www.youtube.com/watch?v=nVIv_uOw1-s&feature=youtu.be

[bill hollingsworth]

Here is some colour footage of Falcons at Oulton Park 1967.


https://www.youtube.com/watch?v=pYQKKlir6sY&feature=youtu.be

[Paul B]

Excellent Footage & great viewing from 67' Brand Hatch Bill, very much appreciated!
Cheers

[Paul B]

Here is some colour footage of Falcons at Oulton Park 1967.
https://youtu.be/pYQKKlir6sY

Some great footage here of some Lotus Mk2 Cortinas Tri-poding around Oulton Park and the Allan Mann Group 5 Falcon sprint.
Certainly put a smile on my dial!
Cheers

[kiwi285]

Graham Hill is really giving that Mk II Cortina some curry until he had a ride into the shrubbery.

[Paul B]

Good spotting Mike, he had his trademark helmet on.
I did not spot that on first view.
Cheers

[Paul B]

I have painted the roll cage now but had some deliberation over what colour to paint it as I wanted something that would be neutral and unobvious. Also I wanted a metal look finish on the cage.
So I settled on a Satin Nickle colour and I think it looks great.

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The cage is Homologated and I have received my log book.

[John McKechnie]

Congratulations Paul, you are now past first base and you have a race car

[khyndart in CA]

Paul,
Again your attention to detail is amazing. Looking forward to seeing you out and enjoying it.
My gift to you this evening is this Jack Sears documentary and especially about the 17 minute 40 second mark, I know you will enjoy.
Cheers mate, Ken.


https://www.youtube.com/watch?v=Ebdtu9Jar7w

[Roger Dowding]

Ken H, what a good video, the story, by the Men of the Time,
Thanks for sharing..

[Paul B]

Ken,
Absolutely brilliant video (post #313), some excellent racing and history.
The Big 1963 Galaxie, John Willment Racing Team, Raced by The late great Jack Sears at 17.40 is one of the very rare factory lightweight Holman Moody racers. (the car was sold on 9/9/2017 at Bonhams for a record £471,900.00) !! more than NZ$900,000
https://www.bonhams.com/auctions/24122/lot/217/
There are some great pics of the original car on this site

The light weight cars were also available through Ford dealers. Amazing how well they did given the size of the huge car but brute HP prevailed
I just love these big beasts and those 7 ltr big blocks thundering around the race track is surely another sight to be seen.

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Bonhams Photo

Thanks very much for posting!

John, Yes your are right all I have to do now is get it painted and assemble the beast.
Cheers

[bmeeke]

By way of an update, earlier this year I sold my 1964 Falcon Rallye Sprint replica after 28-years of fabulous racing enjoyment. It has gone to a new owner in Melbourne who has upgraded from a '64 Mustang. My soft landing was a 2004 Mitsubishi Evo VIII MR which I am using in speed events (time trials) and thoroughly enjoying all the 'mod cons'.

All the recent nostalgia stuff on this thread prompted me to go find some of my old stuff. I was fortunate to spend the 1992 British Grand Prix weekend at Silverstone with (Sir) Jackie Stewart; courtesy of British Aerospace who were trying to sell my company some new aircraft. At the time JYS was heavily involved in Paul Stewart Racing who were contesting F3 and F3000.Their drivers (with whom I got to spend quite a bit of time) were Gil DeFerran and Dario Franchitti. Both went on to great feats in motor racing.

Knowing of my Rallye Sprint racing, JYS had arranged lunch (at the BRDC) with Jack Sears. We spent a leisurely lunch (2+ hours) talking all things Lotus Cortina, Falcon and Galaxie. I managed to get a couple of happy snaps which are attached. I was saddened to hear of Jack Sears' death in May this year.

When I find them, I'll also post some details of my visit to Alan Mann on another trip to the UK.

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[Paul B]

It must have been a fantastic trip Bill, and being able to have lunch and talk to two racing legends.... epic!
Looking forward to seeing your post regarding your trip to meet Alan Mann from Alan Mann Racing UK, another epic trip for you.
Thanks very much for posting.
Cheers

[bill hollingsworth]

The close cousin of the 1964 Falcon Sprint.
https://youtu.be/zx5ibowTLlE

[Paul B]

Thanks Bill,
The Mercury Comet Caliente 427 A/FX where a fantastic machine. Ford claimed 425hp on the high riser engine but it was more like 525hp at 7200 rpm.
Great to see such a nice example of an original survivor car.
Certainly gets my blood pumpin!

[Paul B]

Well it has been a big weekend getting the Falcon Rallye Sprint in for pre-paint primer. The car is looking great. It will come back to my garage and will be carefully hand blocked for the final colour spray.
After this point, it will get a very light first cut with 320grit then a guide coat applied and moderate 400grit longboard, then a light 500grit.

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[Bruce302]

This is getting exciting, I like the progress. Nice work son.

[Steve Holmes]

Well it has been a big weekend getting the Falcon Rallye Sprint in for pre-paint primer. The car is looking great. It will come back to my garage and will be carefully hand blocked for the final colour spray.
After this point, it will get a very light first cut with 320grit then a guide coat applied and moderate 400grit longboard, then a light 500grit and a finishing block with 600 grit.

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Woohoo!

[Paul B]

Thanks Bruce & Steve,
It certainly has been a marathon undertaking restoring this machine. But a very enjoyable project.
Here is a short time line

The tear down, rust repairs, panel beat etc
54832

Full body Acid dip strip, the body looked like a brand new after the dip strip
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Protective steel coating applied, then zinc coated all inner sub frames, A pillars & C pillars
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Epoxy urethane etch primer, (all steel body at this stage) 289 K HiPo motor being built to FIA H-M spec's
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Fiberglass panels fitted and bespoke doors made as per FIA 1250 and MSNZ Homologated roll cage fitted
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Body work done and 240 grit sanded for pre-paint primer
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[Paul B]

In the spray booth 1 coat of epoxy urethane and 3 coats of primer (see post #320 for more shots)
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Primed car ready for block down
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It all looks so much easier posted up like this

[Kevin Hirst]

In the spray booth 1 coat of epoxy urethane and 3 coats of primer
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Primed car ready for block down
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It all looks so much easier posted up like this

Looking great Paul, just wondering if you are going to use the fan belt system as on the motor at present,these skinny belts seem to the most unreliable setup, could you use multi rib or toothed belt instead or would that take away the originality, keep up the great work, wished I lived closer so I could give you a hand with the sanding.

[Paul B]

Hi Kevin,
The plan is that the car will be built exactly the same as 1964 as per the FIA homologation 1250. I do not want to run anything at all modern on the car. So yes I will use the old school V fan belt system, the 289 K Hi Po engines had a larger pulley wheel on the alternator to help at high RPM. I also will look into running twin V belts driving the water pump.
I am also planning to use a factory twin point distributor.
These systems ran very reliably back in the day, so correctly set up and installed should also work fine.
Thanks for the offer of the sanding too!
Cheers

[bill hollingsworth]

A Japanese 1964 Falcon.


https://www.youtube.com/watch?v=NyY3l9tJIYE&feature=youtu.be

[bill hollingsworth]

They built some speccy Falcons in 1965.


https://www.youtube.com/watch?v=1_VKwOT4W7g&feature=youtu.be

[Paul B]

The 427 SOHC (cammer) "B" Falcons were certainly very fast machines back in 64 & 65.
I believe they ran sub 10 seconds on the 1/4 mile.
The cammer engines are nothing less than a work of art and back in the day ran 600hp straight out of the crate from Ford or Holman Moody.
The drag racers got a hold of them and supercharged them to 1200hp.
Great stuff!!!

[John McKechnie]

Paul...you have to stop dreaming and get back to sanding you still have the 400, 500 and 600 to get through. You dont want to wear your fingers out on here.

[Paul B]

Yes boss
back to sanding it is

[Paul B]

Update... Still sanding and sanding. The shell is almost done and will be painted very soon, That is the bulk of the work. The bolt on Fiberglass panels will be much quicker to do.
I dropped the Kelsey Hays 15 inch steel rims (which was what was actually used on the Monte Carlo Falcons) and 3 spare 15 inch rims into the sand blaster and had them blasted, zinc coated and painted black.

Before:
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After:
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I will likely run some 15" Dunlop CR65 or Avon CR6ZZ on these rims to keep it real.

Not planning to use these steel rims on the track as I also have a set of 15" American Racing Torque Thrusts for the track which I will likely use Hoosier tyres with.

[Paul B]

I have been working on the under floor this week, I have sprayed 1 coat of epoxy urethane and 1 coat of primer, it is getting a light 400 sand (and sand out a couple of runs) and then I will spray the finishing coats of red oxide

56173

Right rear wheel arch
56174
You can see the black seam sealer that was applied earlier seems to disappear when its painted.

The original 1960s seam sealer hardens after 50 years and cracks. This was all removed when the car was dip stripped
The modern seam sealer is very strong and durable stuff, it also has a level of flexibility and does not split or crack. When applied to a correctly to a prepared surface, it not only seals all the spot weld construction points/seams but it also adds a very strong bracing factor which supports the spot welds and seams.
Best of all it looks just like the original stuff just better.

[Paul B]

I restored the front headlight buckets and installed new Right hand drive Ford branded sealed beam units

Before
56407

After
56408

Its all available new reproduction, but you cant beat the original parts when they are restored

[Bruce302]

Looking good Paul, but surely the factory cars had runs in the paint, should you have authentic Ford like runs in your paint ?

Just sayin'

[Paul B]

There will be a few runs in the underfloor paint, as they were in the day. Its actually quite tricky to spray the underfloor with all of the odd shapes, guess thats why there were runs in the paint on the original cars when built. But its lookin good so far.
I will post up some finished photos when done.

[Paul B]

The first finished surface is the one you see the least, the under floor & chassis.
I have sprayed it with the Red Oxide finishing coats (4), the same as it was built in 1964.

The pictures have been taken with a flash and parts of the pic's look so much lighter red than it actually is. The actual colour is a very dark red

Under right door (this picture is the actual colour)
57041

57045

Rear fuel tank area ( I repaired the top corner of the fuel tank area, top left side as you see it )
57042

View from diff facing forward (I replaced part of the left rear floor)
57043

Right rear wheel arch (I also replaced the lower rear fender, it had to all be replaced 50mm up, inside and outside, had to make new panels by hand as nothing new was available)
57046

[Steve Holmes]

Beautiful work Paul! Its really looking good.

[Oldfart]

Bloody marvelous

[Paul B]

Thanks Steve & Rhys,
The pictures are not very good, It looks like fire engine red!
It is actually a very dark red and looks much better in natural light.
Cheers

[kiwi285]

Looking fantastic Paul. I'll bet you're getting excited now yourself seeing all that hard work coming to fruition.

[Paul B]

Thanks Mike,
Yes, very keen to see a finishing coat on this project. I can see a time when sandpaper maybe not prominent in my life!
I am working on the body shell, it has had a 320 & 400 sand all over and the roof has had a 500 sand, I will finish the 500 sand on the body shell next week and its ready for paint.
Cheers

[Paul B]

57210

[Roger Dowding]

Too True - a bit like my collectables " ohh they have been on order for years !! and what a bargain "[ they apply the rule to buying shoes ?? ]


57210

Paul - your cars bigger brother.

57216

[khyndart in CA]

Paul,
I thought of you as I wandered around a local car show, Solvang, California, I hope you don't mind if I share these.

57259

57260

57261

57262

57263

57264


(Ken H photos )

[Paul B]

Thanks Roger & Ken,
Nice to see another big block 427 T/bolt Roger.
Thanks for the pics of the 63 Fairlane Sport Coupe Ken, many of these came out with 289K hipo engines but with the earlier 5 bolt block as opposed to the late 64/5 6 bolt block.
Cheers to all!

[khyndart in CA]

Paul,
The "Wheels and Windmills" Car Show is held a week after the Laguna Seca historic weekend so next year you can pop in and take a look as you head down to LAX. (How's that for a plan. You would enjoy meeting some of these folk. I will even buy you lunch.)
They have all sorts of vehicles, such as my friend's 1951 "Baldwin Special" that his father raced and he has beautifully restored it.
But as you can see it can not be touched !
57265

You could try this all weather hood / bonnet arrangement allowing you to work on the engine area in sunshine or rain !
57266

This is a typical scene at Solvang.
57267

This great Pontiac behemoth 2+2 was sold back in the days when gas was 35 cents a gal.
It only has 45 miles on the odometer !
57268

57269


Here are some of the cars from last year's show at this site.

https://wheelsnwindmills.com/gallery/index.php

(Ken H)

[Paul B]

Ken,
Love the 1951 Baldwin Special, Beautiful Restoration!! here is some blurb on it:
This the fourth car built by Willis Baldwin of Santa Barbara. It was raced from 1954 thru 1960 by Wm. Hanssen at tracks such as Palm Springs, Hanson Dam, Santa Barbara, and the famed Pebble Beach circuit. It is based on a shortened 1947 Ford chassis and is powered by a Ford Flathead V8 with an Ardun overhead valve conversion. The suspension and running gear is Ford.

[Paul B]

Pic of the under floor and chassis now painted.
More pics on pg 17 post #337
57471

[Steve Holmes]

Nice work Paul. Awesome effort.

[Paul B]

Thanks Steve,
Its not a simple job spraying upside down and with all the different angles and shapes under the floor to get nice coats from the spray gun. but it looks very OEM which is what the build is all about.
Next job is get the shell into the finishing coat hopefully in a week or two.
Then final sand on the bolt on panels and they get sprayed in about four weeks from now - all going well.
Cheers to all.

[khyndart in CA]

So Paul
When do you do the acid dip and put on the vinyl roof ? :)
Ken H

[Paul B]

So Paul
When do you do the acid dip and put on the vinyl roof ? :)
Ken H

Its no 1969 Penske Camaro Ken, I don't know how those cars held together during racing, some claim they lost 30%-50% of body weight by acid dipping. I cant imagine a 50%weight loss.
Bush maths = if the steel was 1mm thick back then, a 50% loss in weight could be 0.5mm steel. Cant see how that would work. Probably fold in half in the corners!

[Steve Holmes]

Its no 1969 Penske Camaro Ken, I don't know how those cars held together during racing, some claim they lost 30%-50% of body weight by acid dipping. I cant imagine a 50%weight loss.
Bush maths = if the steel was 1mm thick back then, a 50% loss in weight could be 0.5mm steel. Cant see how that would work. Probably fold in half in the corners!

They did some pretty heavy dipping back then. All the factory teams did. I spoke to a guy a couple years back who builds race cars, and he stopped acid dipping body shells and instead now blasts them. He said there was only about a 20kg saving in the dipping. But I know the Trans-Am teams did some pretty intense dipping.

[John McKechnie]

Try picking up a 20 kg item, you can get a bad back or hernia.....20 kg is a lot.
Norm Beechey did a fair amount of weight saving on his Monaro- reading the write up of his build , dont think that was ever acid dipped..can anyone confirm ?

[Oldfart]

I know of a certain car which was being prepared for B&H way back when. A mysterious fire in the workshop meant that the shell was somewhat damaged. Funny that nothing much else was. As no other shell was available :) the powers that ruled were asked to OK that it be rubbed down and repainted, and the go ahead given. It always did look a bit less perfect than most of the others :)

[khyndart in CA]

Paul,
I apologize for trying to have a bit of a laugh as you would be last person in the world to do anything that was not to factory standards and I should not have mentioned acid dipping as it distracts from all the magnificent work that you are doing.
(But I do have some good articles about acid dipping if you are interested !)
You may not want to do that "Bucket List" trip with me now but My "Bucket List" trip was coming out to Taupo this year and meeting so many of you. I will be forever grateful of the hospitality and generosity that made those 3 days unforgettable for me.
Keep up the great work.
Cheers,
Ken.

p.s.
You can get one of the classic acid dip stories from Sam Posey during this YouTube clip.


https://www.youtube.com/watch?time_continue=17&v=6w8IgJ0frPI

57515
Sam Posey's 1970 Dodge Challenger # 77. Laguna Seca. August 19. 2018.
(Ken H photo)

[Paul B]

Not at all Ken, I love a good laugh! and always appreciate your humour. We are all mates so that entitles us to have some man banter fun.
You're on for the trip bucket list for sure, your not escaping that easy!
Great video Too, thanks for that.
If I acid dipped the car that much it had ripply panels I would have to bog it up and that would defeat the exercise!

Steve,
I think there was also some Swiss cheesed 1969 cars, and much interior stripping, maybe cutting out weight also in areas not so easy to see? Imagine trying to weld a new roof onto the a thin steel acid dipped body, the welder would be blowing holes in the thin steel like there was no tomorrow.

John you are right 20kg could possibly be a make or break back then.

With my FIA Falcon build there is about 35Kg saving on all the Fiber panels vs steel, not so much on the doors. I guess with the FIA aluminum bumpers it may be another 10-15kg on top of that.They also had lightweight touring seats in 64' guess another 15kg there, the factory seats are heavy.Also maybe another 5-7 kg with Poly-carbonate windows. But the roll cage makes up for quite a lot. Back in 1964 these cars had no roll cage, as did many.

Cheers to all

[John McKechnie]

OK Paul thats enough on the car losing weight...now what about the driver.
How does you height, weight, body mass etc stack up, adding to that the RHR , balaclava, gloves sox ......
Be like a 10 speed MAMIL..(middle age man in lycra)...remove all hair from body, change lead teeth fillings to light weight compound..the list goes on

[Paul B]

Well John all my hair fell out, shaved the rest off, so saved about 500g there, Teeth have already been done, before each race I cut my nails 5g, wear the lightest clothes which gives me a race weight of 76kg, so watchout I'm a lean mean machine!

[khyndart in CA]

You had better hold it right there Paul, I don't want hear of any other body changes you have made just to reduce the weight !

KH

[Paul B]

Ha ha
Good point Ken, it could get very scary... real fast!

Back to sanding tomorrow to finish the shell off, had a few days away, very nice time!

[John McKechnie]

Now you have done all this work Paul, its safe to tell you this story..
When I lived out in WestWorld, there was a guy I knew called Neil G.
Brother did he have a large collection of cars- this is mid 70s last century- in old massive chicken sheds....thats another story, so we wont go down this path.
Anyway, Neil made replica fibreglass guard for Toyota Corollas , HQ Holdens and many other types and brands when no one else was doing it and NOS was hellishly expensive.
This particular story is about his wifes 1964 Falcon Coupe e and decided to see what panels he could make for it.
Well, the chassis rails ,firewall were steel and just about everything else was changed.
Told me at the time lost more than 280 pounds- not kilos- from this exercise, as well as future proofing it against rust repairs. Also had enough pieces left over to make another Falcon Coupe
Why have I waited so long to tell you this......after all this work, heading towards the finish line, you are not going to undo all your painstaking work and try to replicate this weight loss ...or more.

[Paul B]

Wow that is 127kg, they must have been made very light.
Neat story John, there are some clever people out there.
Cheers

[Paul B]

Here is a great clip to fool you, actually filmed in 2017
https://www.youtube.com/watch?time_continue=66&v=o1MH9SwYVCc

[Paul B]

Here is a great old clip from the 1960 Monte Carlo Rallye, good assortment of cars, great shots of France.
14.5 minutes long
https://www.youtube.com/watch?v=3Ov5brH94H4

[Paul B]

1964 MONTE CARLO RALLYE 2700 MILES OF DRIVING (Old news paper article)57706
57707

57708

[Paul B]

Here is a good read also about the 64 Monte Carlo Rally

https://rallysportmag.com/looking-back-the-rallying-history-of-the-ford-falcon/

[Paul B]

This is Bill Meek in Perth, racing when he had his 1964 Falcon Rallye sprint, He built it 28 years ago or so. He won many events and holds many lap records in this car. This was the first Rallye Sprint Falcon built in Australia to CAMS specs and the car also holds Grandfather rights. Bill conducted a mammoth research mission to build this car taking him to Holman Moody in USA and interviewing Alan Mann in the UK. Over the years Bill has amassed a wealth of knowledge on these particular cars.


https://www.youtube.com/watch?v=HiUvPfeakvU

[Paul B]

Update:
There has been a huge amount of sanding done to finish the car to final paint stage, it is almost finished, only 1 door left to finish.
The entire body inside and out has also been finished.

This was the Fiberglass hood with a powder guide coat applied before the 500 grit finishing sand,
58018

This is the finished Fiberglass Fender & Door, a small amount of rub through that I will spot prime over and re 500 sand.
58019

58020

Finished Fiberglass inner fender panel that I had to make
58021

And here is the finished body shell ready to go to paint
58022

As mentioned earlier, it will be painted Wimbledon White, the factory colour of 1964
There will be some more paint finishing to do, dash, engine bay and blue side stripe, that will be done later after the paint hardens.
The fiberglass moves a little as it cures and there are some small low spots and 1 or 2 high spots that will make it look very original and true to how it looked in the day.... and I am just happy with the look and finish, its not perfect, but they never were.
Hopefully no one will notice as I hurtle down the front straight at a rapid pace of knots.

[Oldfart]

Not trying to tell how to suck eggs, but the Alpine had a plasticiser on the fibreglass bits to cope with the inevitable movement.
It is looking superb Paul.

[Steve Holmes]

Here is another Falcon Sprint recently built by American Muscle Motorsports & Services, in Germany. Although an Appendix K car, they've built it to Trans-Am spec, hence it has no bumpers. Looks cool.

58023

[khyndart in CA]

Paul,
You may have these but I came across this 1964 US. Ford Falcon sales brochure and wanted to share some of it.
I hope that is ok.
58024

58025

58026

58027

( Ken H )

[khyndart in CA]

!964 Ford Falcon brochure continued.

58028

58029

Paul,
Will your car colour / color be similar to what Jim Richards had for his 1964 Ford Falcon Sprint in this 2010 photo at Adelaide's Parklands Circuit ?
58030



(Ken H )

[Spgeti]

Here is another Falcon Sprint recently built by American Muscle Motorsports & Services, in Germany. Although an Appendix K car, they've built it to Trans-Am spec, hence it has no bumpers. Looks cool.

58023

Love the colour scheme Steve.

[Paul B]

Thanks Rhys,
Its always nice to get a car perfectly straight for paint, after blocking this down over 4 times through all the sand paper grades, it is very clear that there will be some more movement in the race weight fiberglass. Albeit after 2 years the movement is a lot less now.
I also elected to use the resin manufacturers recommended formula and method. The inclusion of a plasticiser would have required too much testing and experimental work for me, that aside trying to find the correct plasticiser, so it went into the too hard basket.
The paint work should look very nice as the prep has gone very well, also being white it should be fairly forgiving.
I suppose this build is all about being original so the final finish will be just that.
I am really looking forward to assembly time, that when the good fun starts.
Cheers

[Paul B]

Here is another Falcon Sprint recently built by American Muscle Motorsports & Services, in Germany. Although an Appendix K car, they've built it to Trans-Am spec, hence it has no bumpers. Looks cool.

58023

Looks like the same livery as Roy Pierpoint in the Bill Shaw Racing Falcon on post #157 & #158 - Group 5?
The Cougar looks very cool too, could be a Dan Gurney replica

[Paul B]

Paul,
Will your car colour / color be similar to what Jim Richards had for his 1964 Ford Falcon Sprint in this 2010 photo at Adelaide's Parklands Circuit ?
58030
(Ken H )[/QUOTE]

Ken,
Thanks for the posts, they are great, I like the old brochures, my garage walls are covered with them.
The paint (Wimbledon White) will be a creamy white colour and the blue stripe is a iridescent blue, Guardsman Blue. This is Lars's Car and will be the same as this.
58055

[Steve Holmes]

Looks like the same livery as Roy Pierpoint in the Bill Shaw Racing Falcon on post #157 & #158 - Group 5?
The Cougar looks very cool too, could be a Dan Gurney replica

Thats what I thought too Paul.

58064

[kiwi285]

Love the colour schemes and the Dan Gurney Cougar. You must be getting excited now Paul. As always a superb job.

[Paul B]

Thanks Mike,
The Wimbledon white is a very creamy colour and certainly fits in the period. I watched the first coats being applied today on the body panels. I am aiming for a very "original" look with the paint.
I am very pleased to see colour finally going on. Very happy at this milestone.
Cheers

[Spgeti]

Now you can let your finger prints get back to normal....well done Paul.

[kiwi285]

Looking forward to some coloured photos when we get to Manfield mate.

[Paul B]

Finally the paint day has come!
I Have taken many step by step photos, (will be at Manfeild see you there) Here are some pics of the Fiberglass panels straight out of the spray booth. The panels have not been cut or buff polished yet.
I actually quite like the "straight off the spray gun" look as it pretty much reflects how the original cars would have looked so I may leave it like this. Open to feedback on opinions of course.

Front fenders
58130

58131

Hood
58132

58133

Trunk /boot
58134

58135

The doors will be finished hopefully tomorrow as they were a two colour spray with some interior colour on the inside frame.

[Spgeti]

Superb...

[John McKechnie]

good to see correct terminology...hood, trunk etc.
Soon it will be a car, cant wait to see you at the track with it and see this Falcon fly.

[Bruce302]

Fantastic Paul, the panels look great, I'm with you on having the period 'texture' to the paint, it needs a certain amount of orange peel.
As nice as some of the over restored cars are, and they can be absolutely stunning, they are over restored as far as period correct and proper finish is concerned.

I love the Wimbledon White too. the perfect colour.

[Oldfart]

Holy macaroni, I think we all knew this would be superb, but this is really a whole new level of attention to the right details. Brilliant, and totally in keeping rather than a silhouette car. Total admiration Paul.

[Paul B]

Thanks Spgeti, John, Bruce & Rhys,
So nice to see the fruits of toil and labour come into fruition.
Here are some pics of the fiberglass doors I made, (Pics in earlier posts, pages 8 & 9), the interior colour is red so the tops & bottoms of the original car doors were painted the trim colour, in this case Rangoon red. More pics to follow
Cheers

58142

58143

[kiwi285]

Leave it the way it is Paul - it looks superb. If it gets any more glossy we wouldn't be able to see the car for reflections but then again you might well be able to dazzle the opposition at race time. I am sure a lot of us are thinking 'do you really want to race this car'.

[John McKechnie]

Same thing could be said about the Team Cambridge Monaro...it was always to go on the track, same as this Falcon.Track is a safe place so long as you always look in your mirrors and hold your line.
Be cool to follow this around the track, watching its cornering stance,,,was an Aussie one here some years ago, but that was like it was on rails.
Paul has been to enough Historic meetings to know that our racing is about respecting other peoples cars.
Worst part is cleaning the black tyre marks off the side of the car....no, that didnt come out right....hot tyre pieces flick up onto white paint leaving long black marks, needing cleaning off.

[Paul B]

Thanks John & Mike,
It will probably be safer on the track than the road to be honest. I am surely going to look after it, but it sure won't hurt to stretch the old girls legs a bit around the track. And it will be good fun, really looking forward to driving this one.
Yes, I also agree I will leave the paint as it is
Cheers to all

[bmeeke]

Hi Paul,

It's looking superb mate! Can't imagine how you could have improved anything so far. BTW did you notice that Lars's car has '65 tail-lights?

I might have to cross the ditch to see this beast when its finished.

Cheers.

[Paul B]

Thanks Bill,
I did spot the 65 tail lights on Lars's car, I actually prefer the 64 tail lights.
Bill, you would be very welcome if you wanted to come over when the Rallye Sprint is finished!
Maybe when an Historic race meeting is on too.
Cheers

[Paul B]

I picked up the fiberglass doors yesterday from the paint shop. Mega hours of work making these and preparing for paint has really paid off now.... don't really want to make any more fiberglass doors for a while!

58174

58175

58176

[Steve Holmes]

Woohoo! I love fresh paint! Awesome stuff Paul.

[Growler]

Good to see I'm not the only one who has car parts inside the house!

[Paul B]

I have a dedicated room for car parts now that my son has left home.
When I was in my 20s, flatting, my house looked more like a garage. Engine block as a coffee table, chrome side trim on the walls, tail lights for light shades and the list goes on.
Those were the days!

Thanks also Steve, Hope to post up the painted rolling body in the next few weeks.

Cheers

[Bruce302]

I have a dedicated room for car parts now that my son has left home.
When I was in my 20s, flatting, my house looked more like a garage. Engine block as a coffee table, chrome side trim on the walls, tail lights for light shades and the list goes on.
Those were the days!

Cheers

and so it is now...

[Spgeti]

I have a dedicated room for car parts now that my son has left home.
When I was in my 20s, flatting, my house looked more like a garage. Engine block as a coffee table, chrome side trim on the walls, tail lights for light shades and the list goes on.
Those were the days!

Thanks also Steve, Hope to post up the painted rolling body in the next few weeks.

Cheers

Just an extension of the garage like my office is......don’t have to go out to the garage to look at cool stuff...

[Roger Dowding]

I have a dedicated room for car parts now that my son has left home.
When I was in my 20s, flatting, my house looked more like a garage. Engine block as a coffee table, chrome side trim on the walls, tail lights for light shades and the list goes on.
Those were the days!



Cheers

Remember that back in the 1970's / 80's Allan Woolf had a coffee table made from a geniune Ford BDA block - engine that had some damage- later he sold the block to some guy to rebuild as " ' so ' valuable " by then ..

In my time wasn't in the house but had three incomplete projects, one in the single garage a Austin London Hire car and outside a Sunbeam Talbot and a Sprite plus a donor MG Midget as well as the Carless Day A40, the TR4A and for a time a Dodge Ambulance - don't think the neighbours were impressed as work often went on all weekend - never finshed any of the three projects as always buying another car !!

[Paul B]

That's always the great temptation and dilemma with project cars Roger, so many times during the Falcon build I have been very tempted to buy another project car. But I am actually glad I haven't as it has kept my focus on completion.
I remember car less days, I had an EH Holden as my daily driver then I applied for an exemption sticker (had an X) and got it.
Cheers

[Roger Dowding]

That's always the great temptation and dilemma with project cars Roger, so many times during the Falcon build I have been very tempted to buy another project car. But I am actually glad I haven't as it has kept my focus on completion.
I remember car less days, I had an EH Holden as my daily driver then I applied for an exemption sticker (had an X) and got it.
Cheers

" X " as in Excellent Paul B .

The sticker

58256

[Paul B]

Update:
It has been a very long wait to get the body painted, so hopefully it will be before or around Christmas.
In between time I have finished restoring all of the other small ancillary parts including the heater and demister.
Here are some pics of the finished job
View of fire wall side
59073

view of interior side
59074

A bit boring, I know, It will be a lot more interesting after the car completely is painted and assembly starts

[Paul B]

I took the rolling body in for the first phase of paint. The dash, floors, firewall, engine bay and all of the dash parts plus engine bay parts were all painted

59389

59390

59391

59392

59393

59394

[Paul B]

Also the front engine bay and inner apron panels, The suspension will be changed out, rebuilt and restored after the paintwork is complete

59395

[Spgeti]

Stunning work Paul after months of body prep.

[Steve Holmes]

Wow, that is just so impressive Paul. Great work.

[kiwi285]

When that car first arrives at a circuit the people will be standing round admiring all of the work that we have read about over the rebuild time. Lovely work mate.

[Allan]

When that car first arrives at a circuit the people will be standing round admiring all of the work that we have read about over the rebuild time. Lovely work mate.

Do we know when and where that will be yet?

[Paul B]

Do we know when and where that will be yet?

I will try and get a time line together for completion, it should go a lot quicker once the paintwork is finished, I think we will be talking months now.
Still have to finish the engine build, diff, plus rebuild/restore a few smaller parts and wait for some more parts from USA.
(then its on to the next project)
Cheers to all

[khyndart in CA]

Paul,
Before you get too excited take a look at the video at the end of this site and remember to be aware of the "little Guy" !

59499

https://racecarsdirect.com/Advert/Details/94308/1964ford-falcon-sprintfia-appendix-k-race-car


Ken :)

[Noel]

59513

59514

59515

Neat build thread. Have owned my "64 Sprint for just over a year, 289, 4 speed. Great cars.

[Paul B]

Paul,
Before you get too excited take a look at the video at the end of this site and remember to be aware of the "little Guy" !


https://racecarsdirect.com/Advert/Details/94308/1964ford-falcon-sprintfia-appendix-k-race-car


Ken :)

Thats a great video Ken, sure do have to watch those minis, they are cool machines!

Thanks also Noel for pics of your super nice Rangoon Red Sprint, what a fine example!
Let me know if you need some parts etc.
Cheers to all and thanks for your comments!

[khyndart in CA]

Paul,
If you run out of things to do in NZ I am sure you would fit right in here;
http://www.holmanmoody.com/

http://www.holmanmoody.com/rally_gal.html

59526
A Holman Moody prepared 1964 Rally Falcon in the Monte Carlo Rally. Fifteen Rally Falcon team cars were originally built by Holman Moody.


(Ken H)

[Spgeti]

I think he needs a Mini to match the Monte Carlo Coon.....

[John McKechnie]

Definitely needs a Mini....can always fit the Continental kit that allows for the carrying of a spare little car on the boot.

[Paul B]

Yes a mini would be cool, then I could have 2 monte carlo rallye cars

Paddy Hopkirks winning mini #37 for 1964 Monte Carlo Rallye
59559

1968 Monte Carlo Rallye mini
59560

[khyndart in CA]

Paul,
This could be your next Christmas card scene.
59568
Go for it mate, I have some parts here that Judy wants me to get rid of and that could be to you !

(Ken H)

[Paul B]

Ken,
Does it come gift wrapped in the barn? I will wait for next xmas!
Cheers

[Paul B]

I took the rolling body in for paint yesterday, so we masked it all up for the final paint and prepped the body.
(prior to taking it in I gave the whole body a very light 500 grit sand)

59569

59570

59571

All ready for the final colour

[Paul B]

And today the final paint was sprayed, I was really chuffed with the job, just the right amount of orange peel to make it look like it did in the day.
Very happy with the job, you never know exactly what it will be like until its painted so nervous times.
I bought the car back home and have left it in the warm garage for the paint to harden over the next couple of weeks.

59572

59573

59574

59575

59576

59577

[Oldfart]

Another milestone. I'm guessing it will be hard to stop yourself wanting to progress assembly!

[Spgeti]

Home straight......Yeah Right !

Looks superb Paul. Take your time and get it right.

Cheers

[Steve Holmes]

Wow, just outstanding!

[Leadfoot]

Hi Paul
Very inspirational, super workmanship. Gives me some great tips in building my 63 rally Sprint.

[Paul B]

Thanks everyone for your comments.
Assembly has started now but only on interior while the exterior paint (PPG Deltron DG) hardens.
I have been also restoring the handbrake, air vents, wiper motor & assembly, this will all be fitted when finished this week. On to the wiring next.

Leadfoot, Thanks for your post, I have a lot of info' on the 63 Monte Carlo Rallye Sprint cars if you need some info' I will be happy to help.
Great to see pics of your car, always keen to see more.
Cheers to all

[Paul B]

Now that the paint has hardened, assembly is now moving ahead well. I ordered a set of Avon 15 inch tyres and had these fitted to the restored Kelsey Hays 15"steel rims (correct for FIA Homologation 1250). The Monte Carlo Rallye export bar on the front suspension towers is fitted and the lower shock tower support bar is also fitted. (correct for FIA Homologation 1250)
Suspension still needs to go in, but wiring will be the next job
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[Bruce302]

Wow, looking fantastic Paul, the fun is definitely under way.
I'll be down soon for a drive.

Cheers.

[Steve Holmes]

Stunning work Paul. I just can't say enough about your efforts.

Do you have a goal in mind for when you want to hit the track?

[Paul B]

Thanks Bruce & Steve,
Planning to have it ready for next season in October.
Any time you are ready Bruce.
Cheers

[kiwi285]

Really beautiful Paul. When all of the parts, in their different colours, start going back in it really brings everything else into focus. Is the engine ready to go in - it looks pretty smart too.

[Paul B]

Thanks very much Mike, The engine still needs some top end work, heads & Manifold and then I can fit it. This is the spare engine, the race engine will come later.
The Graham Hill car #201 ran full upholstery as many cars did in the 1960s.
So I fitted the headlining today, as this needs to go in before the front & rear screens go in. They can be tricky to fit but centering it all and working from the centers outwards is a must. The front is glued in first followed by the back then the sides. There are lots of little tricks to fitting a headlining so best use a car trimmer if you have not done one before.

Just trimming off the ends
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Finished
60264

[Spgeti]

Very neat job Paul.

[Kiwiboss]

Thanks very much Mike, The engine still needs some top end work, heads & Manifold and then I can fit it. This is the spare engine, the race engine will come later.
The Graham Hill car #201 ran full upholstery as many cars did in the 1960s.
So I fitted the headlining today, as this needs to go in before the front & rear screens go in. They can be tricky to fit but centering it all and working from the centers outwards is a must. The front is glued in first followed by the back then the sides. There are lots of little tricks to fitting a headlining so best use a car trimmer if you have not done one before.

Just trimming off the ends
60265

Finished
60264

WOW, you've got me worried now, will you actually turn up and RACE it...……………………….? just remember the first stone clip or scratch hurts the most, from there on its just another dirty ol race cra , ha ha

Dale M

[Paul B]

The first cut is the deepest Dale!
It will go on the track for sure, that's the whole reason for the build. And it will have "patina" as it ages nothing wrong with that. I am really enjoying the build on this one its been really rewarding putting the detail in.
I cant wait to give it a burst around the circuit!
Doing the rest of the wiring now.
Cheers

[khyndart in CA]

Paul,
Fabulous workmanship in every way my friend.
Hey I found this spare engine that you could have as a back-up !
https://www.hemmings.com/parts/item/16298.html
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But don't come to Chicago or Toronto to pick it up as it is only about - 18 C there at the moment !
p.s. Will you have seat belts to hold a passenger in for any Demo laps or just the inside door handle to hang on to ?

(Ken H )

[khyndart in CA]

Paul, ( FYI)
I drive past this corner each day on my way into Moss Motors near the Santa Barbara Airport.
(Read this to see what happens on the next lap.)
http://www.tamsoldracecarsite.net/MartinHillFalcon.html

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(Ken H)

[Spgeti]

Now that’s great photo of real cars....lol

[kiwi285]

Is there anything you can't turn your hand to. I'll line up behind Ken if you ever feel like taking demo runs.

[Paul B]

Mike, Its been years in the making, working and building cars and working in auto upholstery industry eventually when you get old you finally know how to do these things, when actually, you needed to know it all when you were young!.
Demo drive for you and Ken.... That would be my pleasure!
Ken, great picture of the 427 FE tunnel port engine, I would gladly have that in my garage!
Cheers to all & thanks for everyone's input and comments!

[Paul B]

Update: I have been working on the wiring over the last few days and now installed about 80% of it. I am just working on the alternator wiring as the original Monte Carlo Rallye cars were converted to an Alternator so I am reconfiguring the wiring loom.

I am also restoring the speedo cluster to complete the dash set up
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I also fitted the tail lights, rear bumper and tow hook. The Rallye Monte Carlo plate is the same as used in the 1964 rallye as per the Graham Hill car, I need to add No 201 to it.
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After the wiring under the hood is installed and I wire up the battery & exterior cut off switch the wiring will be complete

[Paul B]

I have had a couple of weeks off and then started restoring all of the nuts, bolts & trim clips & brackets etc. Very time consuming but worth the detail to get it all looking schmecko.
The body nuts & bolts & trim clips are 5/16 UNF 24 thread so some parts are not possible to get aftermarket as mustangs and 65 Falcons all went to 5/16 UNC 18 thread so restoration of the correct parts was needed.
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I also fitted the diff bumpers and diff vent, the diff still needs detailing
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It's now ready for doors, trunk lid & front fenders, after I fit the front suspension

[Frosty5]

This is an unbelievable restoration even down to the nuts and bolts. Really looking to the finished product, reminds me of the diligence and perseverance of John McKecknie and the Monaro. Well done Paul.
Cheers Dave graham

[kiwi285]

Dave - at least you know exactly what has gone into the build of the car. Should be able to tick some of the boxes.

[Paul B]

Thanks Dave,
If it goes as well as John's Monaro I will be stoked!

All of the wiring is in now I have sorted the alternator conversion circuitry (which was surprisingly easy) and relocating the regulator due to the engine oil cooler that the Monte Carlo Rallye cars ran in the day. I just need to finish & wrap the rest of the yellow alternator wires and finish fitting to the clip retainers. Then its on to the battery cable from boot to cut off switch etc. After all of that is done I will fit the battery and circuit test the whole system.

60968
Important to note that when looking at the cut off switch it is not just the battery circuit that needs cutting off. The charging system cycles 12v from the alternator (or generator)via regulator to the battery but, more importantly, it is on that same circuit there will be one other larger wire that provides power to the entire electrical system plus the generator light wire. (In my car the large wire runs from the regulator to the light switch to power the electrical system)
So by disconnecting the battery only with a cut off switch may not actually stop your motor as the alternator is still providing power on a running engine, likely sufficient to keep your motor running.

[John McKechnie]

If it went like Johns Monaro-
Body done twice.
Stripe on bonnet,roof and boot lid done twice.
Fuellie heads done twice.
4x 48 IDA Webers overhauled, then 2 years later all new internals
Just had the engine out for sleeve in cylinder.
Engine bay repainted correct colour white.
Seat belt mounting under seat re-positioned
So...how many jobs have you had to do twice Dad.........?

[Andrew Metford]

So...how many jobs have you had to do twice Dad.........?

Only all the bits that got sent out to "experts" to do by the sound of it?? Not so "expert" after all, sadly.......

[Paul B]

If it went like Johns Monaro-
Body done twice.
Stripe on bonnet,roof and boot lid done twice.
Fuellie heads done twice.
4x 48 IDA Webers overhauled, then 2 years later all new internals
Just had the engine out for sleeve in cylinder.
Engine bay repainted correct colour white.
Seat belt mounting under seat re-positioned
So...how many jobs have you had to do twice Dad.........?

Well .... where do I start? I have redone a few (a lot) jobs that I have not been happy with, there will be some teething issues upon start up with a full rebuild, but most of it I can only blame ME because I have done all of the work! apart from spraying the etch, primers & finishing coats. Soo.... no pressure at all!
I actually meant, if it drove as well and as fast as John's Monaro I would be stoked.

[John McKechnie]

And I was with Angus this afternoon, he started the Monaro, its ready for next weekend...none of his work has had to be done twice. Thats why I took it there.

[Parnelli]

Thanks Dave,
If it goes as well as John's Monaro I will be stoked!

All of the wiring is in now I have sorted the alternator conversion circuitry (which was surprisingly easy) and relocated the regulator due to the engine oil cooler that the Monte Carlo Rallye cars ran in the day. I just need to wrap the rest of the yellow alternator wires and finish fitting to the clip retainers. Then its on to the battery cable from boot to cut off switch etc. After all of that is done I will fit the battery and circuit test the whole system.

60968
Important to note that when looking at the cut off switch it is not just the battery circuit that needs cutting off. The charging system cycles 12v from the alternator (or generator)via regulator to the battery but, more importantly, it is on that same circuit there will be one other larger wire that provides power to the entire electrical system. (In my car the wire runs from the regulator to the light switch to power the electrical system)
So by disconnecting the battery only with a cut off switch may not actually stop your motor as the alternator is still providing power on a running engine, likely sufficient to keep your motor running.

Hi Paul, Been following this build on T.R.S. and offer my congratulations on such a fantastic job. As per your comments on the wiring cut off switch , you are bang on re stopping of the engine after alternator conversion. I struck exactly this situation on my Mustang . Initial start up and cam run –in then flicked off the ignition switch only the have it keep going. Pulled the battery lead off and still carried on. Luckily a 4 speed car , so jumped in and stalled the engine to stop it. Was all nearly 20 years ago so have forgotten the exact fix I used , a simple diode in the wiring so it couldn’t backfeed from memory ! Looking forward to seeing this on the road and track. Regards

[Paul B]

Hi Paul, Been following this build on T.R.S. and offer my congratulations on such a fantastic job. As per your comments on the wiring cut off switch , you are bang on re stopping of the engine after alternator conversion. I struck exactly this situation on my Mustang . Initial start up and cam run –in then flicked off the ignition switch only the have it keep going. Pulled the battery lead off and still carried on. Luckily a 4 speed car , so jumped in and stalled the engine to stop it. Was all nearly 20 years ago so have forgotten the exact fix I used , a simple diode in the wiring so it couldn’t backfeed from memory ! Looking forward to seeing this on the road and track. Regards

Hi Parnelli,
Thanks for your post! Very true and good advice with the Zener diode installation, to stop engine run on for a street car generator/alternator conversion (depending on the OEM wiring configuration).
I think it goes into the wire to your generator light to stop back run of current when ignition is switched off, as you say.
Cheers

[Paul B]

I have wired the rear mounted battery cables today from:
The battery mounted in the trunk to,
The interior dash cut off switch to
The exterior cowl mounted cut off switch to
The solenoid under the hood.
The battery/ignition current feed wire from the regulator will be redirected to the hot/current side of the interior cut off switch.
To complete this circuit:
A New wire will be fixed to the cold side of the external cut off switch and then fixed to the ignition

This will allow the battery/alternator circuit to still function correctly while isolating the rest of the electrical system when either cut off switch is OFF/open. Both cut off switches will need to be ON/closed for the car to run.
But either cut off switch can be switched off to stop the car.

The Zener diode (as mentioned by Parnelli) will be also added for safety to the 12v hot side of the generator light wires(the engine off hot feed) to allow current to travel from Regulator to the Gen' light only, but not back flow through the other 12v wire connected to the generator light when the engine is switched off.

If you can be bothered reading all that confusing blurb!

Here's the pics
60990

Still need to fit wire retainer clips
60991

The original Monte Carlo Rallye cars had the battery wire fitted inside a rubber tube as this picture shows.
60992

[Leadfoot]

Hi Paul
What are your plans regarding a firewall between the passenger compartment and the boot/trunk area. Are you going to retain the original fuel tank location?

[Paul B]

Hi Lou,
Thanks for your post, The 1964 Falcon Original Monte Carlo Rallye cars had 102ltr capacity, approx 60 ltrs in the OEM tank and 42 ltrs in another tank which was mounted in Boot/trunk just above the diff or thereabouts. So I will create the same but the 42ltr tank will be a race fuel cell to comply with rules. If I run full OEM upholstery I dont think I need a rear Firewall, But I have also fabricated some .7mm aluminum plates to screw in behind the back seat which will seal off the area if required.
The original tank will remain (it has been restored and Tank sealed)
Cheers

[John McKechnie]

Paul...I was told to seal off between the cabin and the boot.
No holes between cabin and boot, cabin and engine bay, cabin and ground.
Seats are not seals, avoid disappointment on the day and fit those plates.

[Paul B]

Thanks John,
Good advice, Probably much safer too, I will install the aluminum plates.
Cheers

[Paul B]

Update:
All the wiring is in now, just some tidy up detailing work to now. So I started fitting the body panels today. It really makes all the difference doing the pre-primer panel pre-fit and gapping, then on the body and when primed pre-paint, because fitting after the paint is applied is super easy, it all fits like a glove. Always consider the thickness of the primer and finishing coats with regard to all panel gaps.
Fiberglass doors - as per FIA homologation 1250
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61363
Fiberglass fender - as per FIA homologation 1250
61364
Fiberglass trunk. - as per FIA homologation 1250
61365
Fiberglass fender - as per FIA homologation 1250
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61367

[Oldfart]

Wow! (Nothing else to say)

[Allan]

All that fibreglass, a good puff of wind will blow the thing over. Glorious job!!

[Paul B]

Yeah, to true Allan, and I might get my doors blown off!

[bmeeke]

Yeah, to true Allan, and I might get my doors blown off! I swear the panel fit you have achieved is better than a production (steel-bodied) car, let alone a bodied-up plastic version. Truly amazing work Paul!

[Paul B]

Thanks very much Bill,
Just the factory 1/8 inch panel gap as in the 1964 manual. Fitting the panels correctly makes a lot of difference. The trunk lid has a little deviation as you would expect from Fiberglass as it pressure closes against the rubber seal.
I put a few hours into the Fiber panels to make them fit. Paid off now.
Cheers

[Paul B]

Today's effort in the sweat shop, more bodywork and interior assembly. The car will be initially assembled as they were when leaving Holman Moody and I will register it for the road etc. After that I will fit the roll cage, race seats and the rest of the paraphernalia to get it on the circuit.

61456

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[Paul B]

I have now got the rest of the fiberglass painted panels fitted, the engine & gearbox still needs to go in and glass and trim also
61741

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I have now moved the car out of the workshop and will be relocating to another in the coming months
61743

[khyndart in CA]

Beautiful workmanship Paul.
It looks better than new.
You have come a long way mate.
61744

61745

p.s. I keep looking for a certain calendar on the wall !

(Ken)

[Spgeti]

Looking good Paul. Job well done and I am sure it will inspire a few more older cars to be built.

[Bruce302]

Paul, That looks absolutely stunning. I can't wait to see it up close.
Excellent work.

[John McKechnie]

as in rear vision mirrors up close?

[Paul B]

Ya never know John, I might be looking at you in in my rear vision mirror... up close.

Thanks to all for your comments of motivation that keeps me on task more than you think!
Calendar is on the wall Ken, thanks very much!

[kiwi285]

Another garage to work in - hope you have a bit more room to complete that great looking Falcon.

[Paul B]

Another garage to work in - hope you have a bit more room to complete that great looking Falcon.

Thanks Mike,
Getting close to the home straight for completion.
Cheers

[Paul B]

Its been a long wait folks! the Falcon has been in storage for 5 months while we relocated. The car is now firmly ensconced in the new workshop, just some more set up and then its on to finishing it off.
On the trailer waiting to be unloaded
63203

Back in the new workshop
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[khyndart in CA]

Paul,
It is good to see your new work area and home with everything looking immaculate (as expected. ) and plenty of room to hang that calendar !
I was thinking of you when I was at Laguna Seca recently. This 64 Falcon has the original paint !.
63209

This was a sweet unit.
63210

Looking forward to your inputs.
Cheers,
Ken

[khyndart in CA]

Can anyone spot the difference between how Paul keeps everything in order and how Hyndman operates with "stuff" lying everywhere and his clothing is a mess. ( But the end result turned out well.) I may not be doing this type of work for a while as I am having right hand surgery this week which may include fixing the lump in the thumb (it can be seen if you look closer ) caused by an old rugby injury Kereone V Otahuhu in 1969 so I have delayed it for 50 years !
63213
(That is a very early Austin Cooper gearbox.) (Hyndman's garage.)

63214
(Paul's garage.)


(Ken H)

[Paul B]

Well Ken,
At least you are getting something done! I have to get a move on as the Falcon should have been running by now! The only problem with a tidy workshop is that I cant find anything!!!
More updates to follow, and Calendar still needs to go up.
Good luck with your hand surgery too Ken, hope all goes well!

[khyndart in CA]

Paul,
What helped me great deal, is if you look closely there is a lazy-boy chair by the door facing a large screen TV and just outside is a covered hot-tub, all necessities for an old rugby player !

Ken

[Oldfart]

The well know "thinking chair", no room in my garage for one of those :(

[kiwi285]

Well Ken,
At least you are getting something done! I have to get a move on as the Falcon should have been running by now! The only problem with a tidy workshop is that I cant find anything!!!
More updates to follow, and Calendar still needs to go up.

Great to see that you are settling in again and trying to remember where everything is and what the next job is. Looking forward to catching up again soon and I hope that all goes well for you.

[Paul B]

Thanks all for your comments and input!
Here is a great clip about Ralph Moody from Holman & Moody and some terrific back ground and history from those early days of racing.

https://www.youtube.com/watch?v=DaJ7x7iRoFQ

63570

[Paul B]

Great article here about the 1964 Holman Moody NASCAR Galaxie resto job

https://www.hotrod.com/articles/1964-nascar-galaxie-rises-dead/

[John McKechnie]

Most impressive part of the article to me was that he wanted period parts, not modern go fast, as his focus is Historic racing

[Paul B]

Yes agree John that's the way I like to see these cars and appreciate them in their own era and period of technology. It sure is an impressive build.

[John McKechnie]

yep, and he wanted it on the track , not sitting in his garage....................hint, hint.
See you next weekend

[Paul B]

I am copping a bollocking for my tardy progress this year and quite rightly so! We have had significant property movement going on behind the scenes, plus 1 month in Europe..... no excuses now though!

[Paul B]

Here is another great video narration of NASCAR. It and hour long, better than watching TV though!

https://www.youtube.com/watch?v=lHxSxvrtHhk

[Oldfart]

Great to spot on Facebook that Paul is back on this super project.

[Paul B]

Thanks Rhys, Our relocation and trip overseas and some family matters took up a massive amount of time so sadly the car took "back seat" for a long while.

Anyway back into it now, so I have been restoring the stainless steel bright work exterior trim, 55 years of dents, I needed to panel beat out and then polished. The roof rail trim and rubbers have been fitted
64906

I have also restored and installed all of the window mechanisms oiled and regreased everything
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64908

And now fitted and adjusted all of the side glass, door rubbers and door strikers (I had to make some striker shims as the thicker fiberglass meant that the latch inside the door was set back into the door further) after all that it all fitted very well considering the different dimensions with the thicker fiber glass
64909
I need to use longer screws to fit the door latch to the door to allow for the thicker fiberglass
64910
The door gap rubber seal has passed the sheet of paper door close test and the doors seal very well

64911

[Bruce302]

Looking very good Paul, can't wait, etc etc.

[Paul B]

Thanks very much Bruce,
I installed the rear window today with the new rubber and also polished the stainless trim inserts with cutting compound and calico wheel.
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[ERC]

Beautiful job.

[Paul B]

Thanks very much Ray,
I fitted the trunk and hood pin cable retainers which I made from stainless rigging cable. Fitted all of the rubber floor plugs, Fuel line, rear brake line and front Handbrake cable etc.
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[khyndart in CA]

Paul,
It is truly a marvelous restoration you are doing.
I just wonder how you will get that steering wheel that is leaning against the wall, hiding my calendar, installed ?
Cheers,
Ken

[Andrew Metford]

Very nice work indeed. First event concours on Saturday, followed by racing on Sunday?

[nigel watts]

I saw this last Sunday at the Oilers Hot Rod Club's brekkie meet here in Tauranga - A bit different to yours.

65150

[Paul B]

Paul,
It is truly a marvelous restoration you are doing.
I just wonder how you will get that steering wheel that is leaning against the wall, hiding my calendar, installed ?
Cheers,
Ken

Hi Ken, that is a teak ships wheel 6ft high and weighs about 75kg ...too heavy for a race car :)
the calendar is in the workshop next door, prominent position on the wall of course, thanks!

[Paul B]

Very nice work indeed. First event concours on Saturday, followed by racing on Sunday?

Thanks Andrew, I need to get it going first and iron out any bugs, do a test day at manfield first. Cheers

[Paul B]

I saw this last Sunday at the Oilers Hot Rod Club's brekkie meet here in Tauranga - A bit different to yours.

65150

Thanks Nigel, That the Aussie version of my Falcon, they share; roof, glass, floor pan, sills & seats (A few other bit & pieces) and that's about it. This Falcon was the first year of the Aussie break away design model (from USA design) Getting hard to find nice Aussie falcon coupes now. Cheers

[Paul B]

Here is a neat clip of a Falcon Rally Sprint in Germany on a hill climb
https://www.facebook.com/104918969574425/videos/1463243463741962/

[Paul B]

The wiring is all finished off now and circuit tested, all systems are go and fully functioning.
65336
Now it is on to suspension and brakes