'65 falcon 2 dr wagon resto

Discussion in 'Station Wagon Projects' started by 65falconwagon, Aug 30, 2009.

  1. 65falconwagon

    65falconwagon New Member

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    Well folks the cowl is in the books as FINISHED! Mark is going to start the last of the big structural issues on this tudor wagon: torque boxes,DS front frame rail, floor pan replacement.....I also got hooked up with a nice RUST FREE PS rear quarter/spare tire well on ebay....The guy actually cut it out of a donor '64-'65 falcon wagon from the wheel housing back to the tail light housing section.....That is going to save alot of fabbing/labor to replace that section....thank god for rust free western parts cars!
     
  2. the Rev

    the Rev senior junior Charter Member

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    your guy sure does some nice work...

    ...ya rusthound:rofl2:
     
  3. 65falconwagon

    65falconwagon New Member

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    I visited Mark again today for an update on the tudor....He has started on the PS by removing the front floor pan....I was fortunate to see that the frame rail is in great shape and won't need replacing....The funny thing is, is that a former owner in the past must have welded another piece of metal over the existing floor pan to try and fix the rust! There was a huge amount of tar up against the rocker which can be said for the other side as well...The toe board was also poorly repaired in the past and is evident in the pictures....I have a replacement donor trans tunnel piece which he is going to weld in as I turn the tudor back to a 3 on the tree....The DS is going to be a different story and I am expecting the worst on that but it will be fixed RIGHT
     

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  4. 65falconwagon

    65falconwagon New Member

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    Today I picked up the rust free spare tire well/PS rear quarter section from Forward Air that was bought off of ebay....What a beautiful AZ rust free piece! This will make fixing my rotted out spare tire well section so much easier to do for Mark over at the shop....I also gave him the toe boards and rear floor pans from Classic 2 Current...he has the front floor pans completely out on both sides and just has to fix the DS front frame rail and cut out the DS torque box....he said it was a PITA to cut out the crappy floor pan fix that a prior owner tried to do....The funny thing was there was a rubber hose in the frame rail which may or may not have been put there from the factory by mistake....anyway Mark is still plugging along and is tickled to death by that little tudor falcon wagon in his shop
     
  5. 65falconwagon

    65falconwagon New Member

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    Mark polished off the PS inner and outer torque box last night so it is FINISHED! He sprayed it with Ospho along with the frame rail....I am going to start drilling out spot welds on the spare tire well/PS rear quarter for the sections that I need. The wheelhousing, trim piece, and any other thing I don't need I will throw on Craigslist for someone to use. My intention is to save on labor cost by doing much of that myself. I figure drilling out a few dozen spot welds will save me well over $300-$400 in labor if Mark had to do it himself
     

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  6. the Rev

    the Rev senior junior Charter Member

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  7. Stormin' Norman

    Stormin' Norman Well-Known Member

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    One of the best rusty floor repair threads that I've ever seen. Excellent details. Thanks.:bowdown:
     
  8. 65falconwagon

    65falconwagon New Member

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    Thanks for the motivation there Stormin Norman! The pictures certainly don't lie do they? Mark has turned his attention to the DS floor repair

    Here are a couple of pics of the DS inner torque box....Mark drilled out the spot welds on the outer torque box and removed the front frame rail...he is going to weld in some patch panels on the rail as there is a little bit more damage....THE LESSON TO BE LEARNED HERE FOLKS IS GET THE COWL FIXED THE RIGHT WAY THE 1ST TIME OR THIS WILL HAPPEN! Clearly this is years of neglect as well as putting a bandaid on things
     

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  9. Stormin' Norman

    Stormin' Norman Well-Known Member

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    I wash mine down every spring and undercoat it all over again, inside and out!

    I'll tell you the floor shift tunnel upgrade in mine came out better than factory. I just love this wagon with every chance I get to drive it. I installed all new Lincoln Premium speakers without any preamp and I get clear quad sound LR/FR separation without any quad setup. She's such a honey of a wagon.
     
  10. 65falconwagon

    65falconwagon New Member

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    Update: I got the donor DS front frame rail piece in from Brian Lukas and what a beauty it was.....This AM Mark was able to weld it in and called it a completed job....next on the agenda is to weld in the inner torque box, outer torque box, and toe board
     
  11. 65falconwagon

    65falconwagon New Member

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    I stopped by Mark's shop this AM and low and behold he has the DS frame rail donor piece, toe board, and outer torque box welded in nice and solid....next up will be the front floor pans along with the tranny tunnel piece and rear pans....that should be done by the end of April
     

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  12. the Rev

    the Rev senior junior Charter Member

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    this car better LUV you after all this;)
     
  13. Svendsen

    Svendsen Active Member

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    Thanks again for the update, excellent work and pics!
     
  14. 65falconwagon

    65falconwagon New Member

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    front floors are welded in along with the donor tranny tunnel piece....next up is fitting the rear floor pans and welding them back in
     

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  15. the Rev

    the Rev senior junior Charter Member

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    gebuz....and I was proud of myself for swapping the carb and rebuilding my starter yesterday....:biglaugh:

    she sure is coming along:thumbs2:
     

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