1963 Futura Build-up

Ok all, here it is. The official build thread for my newly aquired 1963 Ford Falcon 2dr Futura Sedan. Man, what a long model designation. So, I don't know where to start. I found it on ebay, in the classifieds listing. It was local, so I went and checked it out. It was just perfect, sitting there with a 62 donor shell next to it. The guy said $500, so I said I'll see what I could do. I pulled away, and got half way down his drive way when I stopped, bcaked up, and gave him the $50 I had on me for a deposit. The boss loaned me the rest to go buy it. I got it home, and started evaluating the mess I just got myself into. The left rear 1/4 panel is rotted out, and dented.....no biggy, the donor has a good one. The right front was victimized by a ditch impact....oh well, I'll straighten out the frame, and replace the inner fender, and it's getting an aftermarket MII based IFS. So, now on to the other stuff. The original 170 and 2 speed auto are still there, but will be leaving in a couple days. I have a 5.0 from an 86 Lincoln Town Car, that has the roller cam block, and it will be getting stuffed in there, with a T-5 manual tranny behind it. I was gonna keep the 5.0 relatively original looking, but have said to heck with that. It's getting a pair of AFR 2.02/1.60 58cc Chamber, and 185cc intake runner heads. A Comp Cams XFI series roller cam is gonna get stuffed in it, with matching lifters. I want to do a 331 or 347 stroker rotating assembly as well. On top of that, is going to be an Edelbrock low rise dual quade manifold, the one that resembles the old Cobra style, and it will topped with a FAST dual quad EFI system. I am going this route, so that I can use all the "Cobra" marked tin work....valve covers, air cleaner, oil pan, etc., etc. When done, it should look like an old AC Cobra style motor in there, and should flow somewhere in the 450-500 HP range. A 9" with 3.73's is gonna grace the back end, with a 4-bar suspension. All of this is going to be sitting on Shock Wave air struts, all the way around. I'm not sure as to the wheel choice yet, but I want the retro look. I'm going for a hypothetical Shelby Cobra meets Falcon Sprint kind of thing. A "Cobra Falcon" if the had our modern technologies back then. Check out the pictures, they're in photobucket. If some of the images say moved, or what ever, just click it anyway, because they are there.

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Hey Joe

What a cool project. I really like those cars. As an old guy I pretty much ignored or hated those things when they came out. I'm like that. I don't like "anything" at first. But over the years that series of Ford cars has become one of my favorites. I've never had one, but I really likem. I like "smaller" cars-and they are that--I don't know why-maybe just less wasted space for me. Being a truck guy-I've always felt trucks are easier without all that expensive upholstery and headliner etc without the backseat and all. And of course these cars are getting "kinda rare". At least around where I live you don't see many, and they're "unique" styling has-like I said-grown on me over the years. Now I see them as "different" and "very cool". Funny. Anyway there's a couple around here that are mostly stock appearing but modded with motors etc and wheels/ lowered or? And they are totally cool. This is probably a good future choice for a family guy like you too--more room for all. Do you plan to stay with the red interior. Is it useable? From the pics it looks like it is useable or restorable etc. What about the color? Gonna go with black paint again? Is that the OEM color. As I recall the red interior and black paint was an option. Seems to me I mostly saw these as automatic in line 6's. But I guess there were a few 260's c.i.? Is that right?

Really cool. Good luck with that. Keep us posted.

Tom

Wow Dave, thanks for the picture addition. Hey Tom, that black on red is original. The V-8's were not put in ANY Falcons until 63 1/2, and it was the 260 with 2speed auto, or the 4 on the floor. I think the three on the tree behind the 260 would of been possible, but I've never seen one. The 260 version was the Sprint, and from my understanding, it was the only way to get a V-8 in 63. In '64, the 260 could of been had in any version of the Falcon, from the 2 door sedan to the Sprint. 63 was also the first year that they offered the Convertible, and the first for the Hard Top. There were 8??? 2 door Futura Sedans built in 63, so while it is not an extremely rare car, it is still not an extremely common version of the '63 Falcon. I've added a few more photos to my photobucket page, so take a look. I managed to get the entire front inner structure, and the motor and tranny out today. Still a good solid car, but the previous repairs to the nose made it unacceptable to me. The donor car, which there is a picture of, has a nearly flawless front inner structure, so I will be removing it through out the next week, and hopefully have the quarter panel, and the front end ready for reassembly, or already reassembled next weekend. As soon as I get this thing back on all fours again, I'll be going to yank the motor out of the engine donor car. I have also made a final decision on my power plant. I'm going with AFR heads, the 185cc intake version, with the Competition upgrade package, which includes a full cnc port and polish, as well as heavier springs for a slightly bigger cam. I am going to go with the 347 Stroker kit from Probe, and will have the block machined locally. I wanted to go with a dual carb manifold, but I did some homework, and can't find any Cobras that had dual fours on a small block. The cam will be a Comp Cams XFI 248, with 1.6 ratio roller rockers. The total valve lift should be right at about .608 with that combo. The pistons will be fly cut for clearance. I'll be using Dougs headers that use a stepped tube in the primaries. It will flow out a pair of 2 1/2 pipes through a pair of FlowMaster 40's. The block will be girdled at the crank for stability with the Stroker kit. It will also have a girdle on the rocker studs. With the 58cc chambers, I should have around 10.5:1 compression, and with the FAST fuel injection, I should be able to yield around 450-500HP, so an auto trans will be swapped for a T-5. I may tone it down a bit as the actual build gets further, perhaps the slightly smaller version of the cam....XFI236, but for now, I like the combo I am thinking about. The oil pan, the valve covers, and the air cleaner will be the old Cobra type, so it will be a '63 Falcon Cobra.

what yer not gonna shove a big ol' cat into the nose of this one ??????? LOL !!!!!!!!!!!!!!!!!!! cool car cmon lets see how far you get before you start brainstorming and constantly changing things like some of us ........................

Hey Joe

You mentioned Falcon Sprints 260ci etc. And I remember those for sure. And they even made a little Falcon Sprint pickup if I recall. But what I was really thinking about was your comment on planning for an aftermarket Mustang2 type front suspension. I'm sure that's a good idea etc, but I'm just looking for some info--is the OEM Falcon front suspension not
to your liking in general--or is this car just too worn etc and it all needs replacing. I guess I don't really know much about that OEM Falcon front end. Not good?

Tom

No, no Cat in this one. I have concidered a Perkins 4 cylinder though, but it just wouldn't be as fun. Well Tom, I did finally get the time to take a really good look at the front end of the donor car. I also had a chance to thumb through a catalog for old Mustang, which share the same front end. I can get a bolt in tubular contol arm front end, and use the stock front suspension set up. I can get a bolt in disk brake set up, and so, I may not go with the aftermarket IFS kit. The original front end was kind of flimsy, so, I could beef up the fron a bit and make it handle the weight of a V-8, and the power I want to put in it, so as the game gets played, I may change my plans a bit here and there.

Not much to report today. I got the master cylinder off, and got the heater unbolted. I did get the front seat, and front carpeting out. No rust in the front of the car AT ALL, so that's a good thing. I got the instrument cluster removed, and the brake pedal hanger removed. I started in on scrubbing and prepping the fire wall area. I did get the right front toe-board straightened out, since it had a little goober from the front frame rail getting tweaked. I have some minor repairing to do to the firewall, where I didn't get the spot weld cut all the way, and they broke instead of just cutting. It is a really nice solid car to start with, so it won't be too bad to finish getting the front ready for the new front inner structure. I did talk to a body guy at work today. He has a really nice older Mustang. He says that he has only minor modifications, mostly a stiffening brace, and high quality springs, and shocks in his car, and it handles like a dream. So, since I have a really good front end to put under it, I don't know that I'll actually need to swap in an IFS kit. There are a lot of upgrade parts for the 64-66 Mustangs, and they are all the same for the Falcon.

Hey Joe

Its looking good. I'm reminded from your current pic about the Falcon OEM dash board. Kinda
nice looking I think. Nice and simple with that chrome or brightwork etc. Good to hear
there's some early Mustang front suspension upgrades available. That may be to your liking.

Goodluck
Tom

Hey Joe

By the way, I see you've got what appears to be the OEM radio. I don't know if you plan to use it etc. But
its probably already a sought after "collectible". It does look cool sitting in the dash. Or you
could probably use it for trading if you wanted. I'm sure there's some collector out there who wants it.

Tom

I like the simplicity of the interior too. I want to make it look fairly stock inside. I grew up in these cars, and the old Ford trucks, and I like everything about them. The stock redio will likely stay in place, or I may get it converted to an AM/FM reciever with CD changer port in the rear. There's an old man locally that is good at converting the AM radios to FM. For the dash, I will have to add a mechanical oil guage.

A bit more progress has been made. I got parts pulled from the donor car, and am going to finish getting the nose prepped for installing on the '63s body tomorrow. I over cut the quarter panel section, so I have room to trim it to fit. Hopefully, I'll have it back on all fours tomorrow, and maybe have the quarter fixed. Here's a couple pictures

And, now it has all four wheels on the ground. I couldn't spot weld it like original, but I got it all lined up, perfectly, and did a nice tight stitch weld inside and out. It should be as strong, or stronger, than original. The best part, it no longer has a boogered up frame rail like before.

Yeah Dave, I think I will. I am opting against the aftermarket IFS. I found out, that the factory suspension, which is the same as the Mustang, can be easily upgrade to Shelby Mustang IFS for under $500. I am also going to get a set of sub frame connecters. The rear end is gonna give way for a 9". I still have to put in a tie plate for the front frame rail where I have to splice them. I will be putting in a bolt on upper tower brace as well. The frame, in stock form, will handle upto around 300-350 HP, with minimal deflection, but the number of aftermarket stiffening parts is extraordinary, so I shouldn't have much trouble there. I do have to tune down my plans though. I've been building a combo that would make a heck of a weekend strip machine, but I don't need that much. I think that this car will make a hell of a high way burner if I keep the HP range at or around 350-400, and still give me enough to play at the strip if I so desired.

Hey Joe

You're making fast progess. Looking good.

Tom

Not much today. I got the wiring out, the heater box out, and the windshield removed. I had to pull the windshield to get all the headliner out. I might get to the back glass tonight, but if not, then likely tomorrow. Next, will be getting the doors off, and taking it down to the shop for a bumper to bumper steam clean. I want to steam clean it before fixing the left quarter panel, so I can make sure I get all the crud out of there. Once I'm ready to do the quarter panel, I'll get the inner fixed first, and spray the insides of both with that Dupli-Color truck bed coating, and then get the outer quarter skin on, and go back over the inside of that with the truck bed coating. After it's all steam cleaned, I'm going to spray the ceiling, and under the dash, and all the inner structure areas with the bed coating stuff. It goes on really, really nice, and leaves a powder coated look. It's pretty durable too. I've found a guy in Portland that he and his partner are retiring, and he is selling of the Falcon parts they have, so he is rounding me up some parts. I also may have located a complete 89-91 5.0 HO with T-5 manual trans. I don't really need the motor, but it never hurts to have two roller cam blocks. I'm going to go with factory style bucket seats, and will use the bolt on T-5 conversion kit, so it will be a "stock" looking install. Mustangs Unlimited has a factory clone floor shifter lever available for the T-5, so it will really look like a factory car that's been resto-modded. I'm still debating on the aftermarket IFS, mostly because I really want the extra cross-member, and the front steer spindles. It will really make life easier, so I may end up going that route. It's $1295 for a hub to hub kit. The guy in Portland has an 8" Ford rear end too, so that will really help. I have a lot of work ahead of me, and even more so, now that I have glass out of it. I'm at that stage where a complete ground up is just as easy as putting back together, just to take it apart again later, so I think I'm going to take the scenic route, and start from the ground up. If I keep the current pace, I should be able to enjoy it by summer time. No new photos this time, but probably tomorrow.

Hey Joe

That all sounds interesting. Found some Falcon fans in Portland? Ya I'll bet there's stashes of Falcon stuff
here and there. Its the kinda car even "non-car people" kinda like to collect etc. Does that make any sense--I mean non car people? I guess I'm saying it has some attraction "across the board". Kinda like the VW bug I think--especially the early body style like you have. I'm interested in hearing you're comments about all that aftermarket "Mustang type stuff"--steering/transmission shifter stuff etc. I always said that if I were younger I'd get myself a 5.0Mustang because there's so much engineering on the modded stuff/and its available. Its a "big" community. So if I understand you right--and I've never even touched a Mustang2 suspension etc--so I'm totally ignorant--but I guess "front steer" that you mention--means the rack and pinion goes out front etc? of a crossmember or? etc. And you're saying your OEM setup doesn't have a "crossmember" or isn't strong enough/or that its not "front steer"? I've read plenty of articles on installing the aftermarket Mustang2-although I've never done it. And I see the "gist" of how that similar looking crossmember is welded to the frames with "hats etc". And that's stronger or gives you more flexibility to do what you want etc than the OEM? And I'm sure that's correct. People like the Mustang 2 setup. I don't even really know what an OEM Mustang2 "platform" looks like. I guess I"d better do some Googling or look closer at your photos. Sounds cool with what your doing. Keep us posted.

Tom

Joe

You probably know about these guys--but if you don't http://www.welderseries.com/pages/contact_us.htm -this group up in Canada? Ontario? Anyway they manufacture all kinds of hot rod type stuff including Mustang 2 crossmembers/supports etc for the "do it yourselfer" like you. What they do is have "free videos through youtube"--I subscribe to their feed-its just interesting to see what they're doing. I've never bought anything from them, but I would if I needed something. But their take is different than most they sell the "pieces" to their customers who do the finish welding and installing etc. They don't sell a completed motor mount--as an example--they sell you the 4 pieces that you weld to "finish" the motor mount before you install it etc. Does that make any sense? Its less expensive this way -for us- and sometimes they do the "bending or whatever" that is not alway so "doable" at home without pricey tools etc--It all varies, plus they engineer some pretty neat stuff--Lots of Mustang 2 type brackets etc. There maybe something there that you might learn etc. I enjoy watching their build videos etc.

Tom

Yeah Tom, that's pretty much it. The MII front end is a front steer, meaning the rack is in front of the spindles, and it is a weld in crossmember. This will allow me to use rack, and pinion, which is far smoother than box type steering. It easily allows the use of more affordable coil overs, or air suspension, which is very pricey on the stock front end. It also affords me the ability to remove the shock towers, which means enough room for a big block. The T-5 is a small 5 speed, so I won't need to alter the tranny tunnel in the car at all. There is a conversion trans bracket which makes it a bolt in install. The falcon guy in Portland, is a retiring wrecking yard that is just Falcons, and Econolines, and their various "cousins". Adding the 5.0, means roller cam shaft straight from the get go, which means freeing up some parasitic loss, and excess wear on internal components, and a faster revving engine. The real Mustang II front end is very similar to the aftermarket, except that the real ones use a strut rod similar to the stock suspension that's on the car. The aftermarket kits use tubular upper and lower arms, and eliminate the rods, and allow for almost infinite suspension tuning adjustments, and right out of the box, they are a better, more stable feeling front suspension.

Got more done. It's more or less completely stripped. The suspension is the only thing not stripped apart. I managed to straighten out the right front fender a bit, and I might be able to save it. I worked over the left end of the front header panel, and got it straightened out too. All the glass, and all the trimmings are off. The doors are torn apart. I started disassembling the quarter panel repair section, so that I can fit it, and fix the quarter panel on the car. There are more pictures in the photobucket page, but here are a couple from this weekend.

You saying my stuff aint interesting....lol. Actually, you're right. It will start taking shape soon. I've got to work on the quarter panel, and then I'll get started on sanding it, and working it over inside and out. I don't have much trim to replace, and only a few that will need rechromed, so that will be easy. As soon as our settlement checks arive, and we start getting situated with buying a house we're looking at, I'll really be able to start getting this thing under way. I'm also awaiting the opportunity to buy an old Dodge truck from one of our customers, so that I can get the Cummins out for my Big Job. So, I have lots of things on the burner. While, this car is not going to be a perfect restoration, I want it to be a very nice, very clean, and very tastfully done resto-mod. I was in NAPA the other day, and was talking to a guy about it, and he asked why I was "ruining it." He also said "you're gonna put a 350 in it too I suppose." I told him not to ever insult me like that again. I told him I don't believe in putting non-manufacturers power into a vehicle. Since Ford has used various diesels, I can still claim the same principle on my Big Job. I opted against a 4-link on the Falcon. I've been sitting here planning a build, and everything has been geared for extreme performance, track ready action. I want a nice potent daily driver. I'll use Mustang performance leaf springs, to make it handle the increase in power better. A MII front suspension, since it will stiffen the fron end, and make for a whole world of options. I'm also tuning down the engine parts. The ones I was looking at, would of been in excess of 500HP. Now, the new combe selections should keep me in the 375-425 range. It's still going to be along the lines of a "hypotheticl" Shelby built Falcon. I want it to be a pleasurable car to drive with my family, and still be a bit of a street screamer.