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

[Oldfart]

I have definitely run out of superlatives to be able to comment Paul.

[Roger Dowding]

I have definitely run out of superlatives to be able to comment Paul.

Rhys you are not alone, brilliant car.. Thanks Paul B ..

[Paul B]

Thanks guys!
It will be good when it can turn its wheels under its own steam.... preferably rather quickly

[Paul B]

The rest of my parts arrived yesterday from USA, so I could get on with the front suspension. I fitted the upper and lower control arms, new springs, restored the torsion bar, and fitted the HD spindles.
The 1964 V8 Falcons had from factory, heavy duty tierod ends, and matching spindles, the drag link and idler arm housing was also HD (you can see it has 3 bolt idler arm housing on the chassis vs Mustang 2 bolt) . When Holman Moody built the 15 cars they replaced the OEM spindle with another heavy duty larger spindle and also used their own HD spring perch as shown.
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[Bruce302]

Nice

[Paul B]

Thanks Bruce,
I have been fitting the original type Kelsey Hayes 4 pot calipers and rotors, Right side, I needed to rework the rotor back plates to fit the HD spindles. These are the same brakes that were used on the later Mustang GT350s but the Falcon Rallye Sprints also had an in line Hydrovac booster mounted where the battery was.

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This is a picture of the 1964 FIA Homologation 1250 Left Front brakes
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Very interesting, I found an article on Kelsey Hayes brakes and the Chrysler Valiant entered in the 1964 Monte Carlo Rallye also had the very same brakes as the Falcon.

[Andrew Metford]

Not trying to be a rivet-counter, but are grooved rotors period correct??

[Paul B]

No they are not, but they are only decent rotors found so far, most of the non grooved ones are not produced from very good quality material. Still looking, these will do for the meantime till I find something else.

[Andrew Metford]

Didn't know that. Wow. You don't want second rate materials in the brakes, so I can well and truly understand your decision there!!!

[Paul B]

Rotor warping is a real pain especially under track conditions , bedding them and heat prepping helps a lot but if the metallurgy is not up to scratch it can be more rotor change outs and reskimming etc. Cheers

[Paul B]

I made up all of the front brake lines for the master cylinder to booster, booster to junction and to front wheels, then fitted them up. I also finished fitting the brakes and torqued everything down. A lot of brake lines with a remote in line booster but that's how they were made.
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And spaghetti junction,
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[Paul B]

Fitted the anti sway bar and some other parts and torqued the front brake and suspension components down, re checked the camber and caster. That completes the front suspension and brakes assembly.
On to the steering now to finish that off.
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[Andrew Metford]

Beautiful work!!

[Paul B]

Thanks Andrew, Getting there... slowly
I fitted some interior and the front screen with the wipers too, and they work!

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Also had to buff & polish the 55 year old Stainless trim, started with this
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Here is the finished job
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Screen & Wipers fitted also
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[Paul B]

A few more jobs done
Fitted the front upper outer shock tower supports I fabricated earlier
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Also gave the Borg Warner T10 a birthday, this is the first of the Super T10s with 28 spline output.
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It is always interesting seeing the different ways people have reassembled parts over the years in places they should not be.
Also this is a picture of all the RTV I found in places it should not be.
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[Paul B]

I have completed the body and trim assembly and the interior also. The wiring is all done and the alternator conversion with diode install is all completed. ready for engine, gearbox and driveline now.

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So this is the road going version to get it road registered and then it will come back for the roll cage etc, it will be running complete interior as the cars did in 1964.

[khyndart in CA]

Paul,
Your workmanship and attention to detail is absolutely outstanding.
Even the garage floor is spotless. Well done mate.
Although your dear wife must get a lot of credit as she waited patiently for you as you spent time with your second love !

Hey, perhaps one day we can link up and spend some time together..
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(Alamy photo )

Cheers,
Ken H

[bmeeke]

The car looks amazing Paul. I doubt they ever looked that good at any stage of their journey from the US to Monte Carlo. The panel fit is just exceptional. The second stage (post licensing) will be just as intriguing for all of us who have followed the build. Great work!

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So this is the road going version to get it road registered and then it will come back for the roll cage etc, it will be running complete interior as the cars did in 1964.[/QUOTE]

[Paul B]

Thanks very much Ken, Nice to see it at this stage now... finally! hope you are all well there.
Cheers

Thanks Bill, I guess I am trying to emulate what this car would have looked like when it was brand new after leaving Holman Moody. The panel fit is good but not show car level, and the fiberglass has continued to shift a little, so there are a few wallows here and there, only visible when you look for it and get up close and on certain angles. I think, all things considered, it is a very close representation of what they had in the day. Well about as close as I am going to get :) I am finishing the engine now, street version, the race engine is coming later. Cheers

[Spgeti]

I called in today on the way back from Kapiti to see Paul and the car.
The photos are one thing but seeing the car in the flesh is just so different.
Nothing said can do justice to the amazing job Paul has done on his build.
This truely is a world class restoration and the attention to detail is unbelievable.

Paul you deserve the accolades that your extreme effort on your build of this fabulous car.

Well done my friend and I cannot wait to see is debute on the grid in HSC.

Cheers
Bruce

[Paul B]

Thanks Bruce,
I have really enjoyed tinkering around with this project, probably why its taken so long to build! Anyway its on the home straight now.

Dale Mathers from Coastline Automotive has built me an awesome original 9 inch Detroit locker diff and supplied some 31 spline axles etc, very happy with that.

I have also finished the engine (road version) and gearbox, Super T10.
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Fitted up the Hays clutch & pressure plate (same as 1964 original), every thing is ready to go in to the car.
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The Falcon T10 gearboxes had a different tail shaft housing to the mustang (otherwise the same) the shifter is mounted much more forward in a Falcon than a mustang.
Many mustang Falcon parts are not the same such as the clutch Z bar was specific to Falcon and 1964 is different to 1965 as are 6 cyl.
There have been so many considerations to build this car correctly to Ford, Holman Moody and Alan Mann Racing 1964 specs.

[Paul B]

Holman Moody made a huge amount of changes to the car for entry into the Monte Carlo Rally of 1964, but the Falcon needed to remain looking as an OEM production car.
Ford had to comply with minimum production of 1000 Rallye Sprint cars so they offered an actual 1964 Falcon Rallye Sprint for 1964 (RPO) which included all of the Holman Moody parts that were fitted to the 1964 Monte Carlo Falcon Race cars. In turn these cars were actually classed as a Regular Production Option vehicle to meet the criteria for entry into the 1964 Monte Carlo Rally.
I recently managed to find an original 1964 Falcon Rallye Sprint hand book.
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What a find! all of the original part numbers too!

[Roger Dowding]

That booklet is great - to go with the Car well done Paul..

[Paul B]

Thanks Roger,
A real gem there with all of the ford part numbers and also shows Holman Moody part numbers so I know what was made at Holman moody that replaced the Ford parts. Hugely useful.

The engine and gearbox is in the car now, still a few more parts to fit
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Here is a pic from the 1964 car
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[Paul B]

Engine complete ready to fire.
I will connect the external oil cooler later, Radiator with a left inlet will also be fitted later

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Here is a pic of one of the original cars for 1964
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This car was fitted with Girling brakes, the others had Kelsey Hayes front Discs

[Paul B]

I started to fit my diff together, measured the axles and checked the axle length and found the diff housing has been modified sometime in its life. The offset has been altered, so it has gone off to be corrected back to what it should be. After researching the diffs for these cars I have found the most likely diff housing used was a 1959 ford ranch wagon diff housing as this was one of the very few 9 inch diffs with 2 inch wide shoes on 11 inch back plates and drums (which is correct for FIA #1250). This model diff was also a perfect fit into a 63-65 Falcon or 64-66 Mustang.
The diff head was a Detroit locker 31 spline which I have now. So it all should come back soon correct and I can bolt it up.
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[Paul B]

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[Oldfart]

I was going to give my usual plaudits, then I saw the seat. Is that what they used? We can do a lot better for you Paul.

[Allan]

Paul, is the roll cage built to original specs or has it been made to suit MNZ rules?

[Paul B]

Hi OF, The race seat is a USA Kirkey, the upholstery cover was not fitted yet, it is a new old stock seat and period correct for the car even though in 1964 they did not have race seats in these saloons, either factory buckets or a special touring seat was used. But I must have a compliant race seat to be eligible to race. I don't really want a modern looking seat. what seats do you have?
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Hi Allan, The roll cage must be Motorsport NZ homologated, and is, I have the log book now.
In 1964 these cars were actually raced without roll cages as were many saloons.
The roll cage is a bolt in and I have tried to keep it as period as possible whilst also complying to MSNZ regulations.

Cheers to all

By the way, with the roll cage in now, the rear seat back and carpets still have to go in, these are being made as I don't want to cut up the original parts.

[Roger Dowding]

Real progress Paul B, great to see the car this complete.

[Oldfart]

Hi Paul, the email I have for you has failed. I'm still on the one you have used previously.

[Paul B]

I started to fit my diff together, measured the axles and checked the axle length and found the diff housing has been modified sometime in its life. The offset has been altered, so it has gone off to be corrected back to what it should be. After researching the diffs for these cars I have found the most likely diff housing used was a 1959 ford ranch wagon diff housing as this was one of the very few 9 inch diffs with 2 inch wide shoes on 11 inch back plates and drums (which is correct for FIA #1250). This model diff was also a perfect fit into a 63-65 Falcon or 64-66 Mustang.
The diff head was a Detroit locker 31 spline which I have now. So it all should come back soon correct and I can bolt it up.
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So my diff housing has been away getting rebuilt back to the original 59 Ford dimensions in order to keep the car correct.
The axle tubes needed to be cut off and replaced with the correct length
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new axle tubes welded on

[Paul B]

On to the dash and gauges now. The original Monte Carlo Falcon of Graham Hill had the radio removed and a set of gauges and switches located in a custom panel. Graham Hill and Ian Walker had no Music to listen to in the 3500km rally in 1964.
Here is a pic of the dash
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And here is my effort so far, a bit more work required and some paint plus I would like a Smiths Oil gauge and Temp gauge
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I still need a few switches and will complete it this week
The last of my parts arrive from USA in a few weeks to finish the car, The upholstery, livery and diff is being finished soon I can hopefully drive it in 3-4 weeks.

[khyndart in CA]

Paul,
I was driving near home today and saw this beauty parked by a field. The nice elderly lady said it had been in the family since new in 1964.
One does not see a 1964 Ford Ranchero around here very often so I had to share this one.
(Note the smoky haze in the background from the fires near Laguna Seca, 200 miles north of us. )
With a more powerful engine I thought this would make a fine tow vehicle for you.

p.s. I always appreciate your inputs and admire your craftmanship and attention to detail.
Cheers, Ken.

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[Paul B]

Nice Ranchero Ken, 1965 grill with 1964 side trim. Not sure if they came like that in 65.

[Paul B]

On to the last bits of detail, finishing the dash gauges that the Monte Carlo Rally cars had, This was how the G Hill & I Walker car was set up, Each car was a little different. I still need to get the Gauges cleaned up and add labels
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[Paul B]

The diff housing has all been rebuilt to how it should be, beautiful job and fits like a glove thanks to Tim at The Krysler Shop.
I have stripped it back and repainted the housing and fitted it into the car today together with the FIA 1250 Holman Moody brakes & drums.
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The diff head is a Detroit Locker, 31 spline nicely built by Coastline Automotive.
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The brake shoes are 2 inch and have 9 pads instead of the 2 long brake linings. Also a smaller Brake cylinder was used as fitted all as in FIA 1250 homologation.
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The Koni Classic shocks will go in as soon as they arrive from being re calibrated.

[Paul B]

Got some more done last night,

Fitting the gauges, Nice set of Smiths UK, The G Hill car used the original Sprint steering wheel
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This is Bo's car #49 with different Grant steering wheel
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Also starting livery fit out the same as the Graham Hill car
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[Bruce302]

More excellent work PB, I'm hanging out to see that old girl run.

[Paul B]

Thanks Bruce, None more than me!
Have had a couple of set backs, the race radiator (Dewitts) didn't fit, not even close! so another from elsewhere has been ordered, had some header issues and nothing fits any good so Left Manifold coming for USA, will need to airfreight.
Apart from that its nearly there, finish bleeding the brakes, and tune the engine, fit the Driveshaft hoop. and the list of little finishing jobs. Cheers

[Roger Dowding]

Great progress Paul,

Saw this American Falcon at Caffeine and Classics - the October event at Smales Farm.

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A fairly rare car here in NZ.

Cheers
Roger

[Paul B]

Thanks Roger, Looks like some nice machines were there. Maybe get up there sometime soon.

I have finished the wiring loom for the instrument panel and connected the gauges to the engine, Wiring loom for Tachometer is fitted, Front Driveshaft loop is all in and the car is all back together now
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The new old stock Kirkey seat is fitted with new upholstery
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[Roger Dowding]

Great work Paul, just saw the photos on your Fb page, Cheers

[Paul B]

Its go day:o;):p:cool:
Go full screen to view, then ESC when you have finished.



https://www.facebook.com/NZ-Historic-Muscle-Cars-and-Historic-Saloon-Cars-535961669883205/videos/379588899768147

[Leadfoot]

That's a great sound, well done. Let's see some more!

[Paul B]

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[Oldfart]

Paul, you have left out the damage to the rocker panel :)
Now what?

[Paul B]

Haha OF, but wait there's more!
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I hope I don't have this to look forward to.

I read somewhere about a story where Graham Hill had an off in the Monte Carlo Rally and damaged the left front fender/wing, he and Ian Walker had to tie a rope to a tree to pull out the bumper etc so he could drive on.

[Oldfart]

Haha OF, but wait there's more!
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I hope I don't have this to look forward to.

I read somewhere about a story where Graham Hill had an off in the Monte Carlo Rally and damaged the left front fender/wing, he and Ian Walker had to tie a rope to a tree to pull out the bumper etc so he could drive on.

It must have been a solid tree to pull a Falcon bumper out! Yes, keep it straight Paul, and all those other guys out there at the same time as Paul, stay away!

[Paul B]

They had aluminum bumpers on those cars, but still fairly durable.
Cheers

[Paul B]

Ready for Taupo Historic GP this weekend at Bruce McLaren Motorsport Park (23 & 24 January 2021)
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[Paul B]

Click on full screen to view


https://www.facebook.com/paul.berkahn.7/videos/416885396253937

On the dyno for pre race tune

[Roger Dowding]

Go well Paul B, [ and all the others at the Historic GP meeting ]. Understand another "Big " Ford will be there, a Galaxie and the meeting theme is FORD.

The last time I was at Taupo, [ I was reminded of ] was for the A1 GP in January 2008.Still have the ticket.

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Enjoy the weekend Guys - and post lots of pictures.

[ERC]

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Funny that today, I have been transposing, (or a precis), of my 1964 handwritten diary into a spreadsheet - big job, even with just a sentence or two per day.

"19/1/1964 - Benny Hill on the radio - and Graham Hill is still in the Monte Carlo Rally."

Those were the days, when you got almost hourly reports on the radio (BBC) from the Monte Carlo Rally.

I had absolutely no idea that car was the subject of this thread! Have only popped in once or twice. Awesome rebuild - especially impressed with the interior.

[Milan Fistonic]

The car on track at Taupo on Saturday

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[ERC]

Presumably that is the Ian Walker who was the well known team owner/entrant at the time, usually Lotuses as I recall?

[khyndart in CA]

Ray,
You are correct.
Was he related to Rob Walker ?

https://drive-my.com/en/test-drive/item/3714-1964-ian-walker-racing-lotus-elan-coupe.html

[khyndart in CA]

Paul,
The car looks magnificent.
Congratulations, it must be like a dream come true.

Ken

[Roger Dowding]

Presumably that is the Ian Walker who was the well known team owner/entrant at the time, usually Lotuses as I recall?

Was that the same Ian Walker who was involved with Private Entrant Austin Healey cars in Rallying in the early mid 1950's ?
Maybe the question is for Ken H - seeing his answer in post #258

I have this photo of Ian Walker's AH 100 - NWD 394 - event not known;
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and this one of Ian Walker in the 1955 RAC Rally in an AH 100 again - looks like NWD 394 too !!
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Sorry to hijack the thread Paul B..

Great to see the photos of your car at Taupo.

[Paul B]

Thanks Ray, Yes that was the plan to build G Hills #201, and yes Ian Walker was a notable competitor in the 60s.

Roger, your post #560 first photo I think that is Ian Walker on the left with the cap on. Love the Healeys!

Milan, Great photos, Thank you for posting them.

Ken, very happy with the build, but the engine performance let me down and trouble with 2nd syncro, but the car just kept on going (albeit slow), Plenty to do now including a new engine build.
Cheers to all

[Paul B]

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Got a few more pics from Taupo 2021, from Nigel, Jim and Steve

[Steve Holmes]

Great pics Paul!