saving another '65 falcon 2 dr wagon! - Page 2 - Ford Muscle Forums : Ford Muscle Cars Tech Forum
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post #16 of 109 (permalink) Old 11-25-2009, 12:51 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

today I wrapped up cutting off the rest of the roof skin....managed to save two good sheets of metal that I can reuse for other things....only cost me $8 for four grinding discs.....the great thing is that even though the inner structure is rotted out it still is stable
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post #17 of 109 (permalink) Old 12-03-2009, 07:38 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

out looking for a new roof replacement but in no hurry as the car is in the garage out of the elements....have found some possibilities but out in California, Canada, Texas and I live in Florida...I have two possibilities in removing the inner structure along with the ribs

1. remove all the spot welds and remove the top part of the inner structure leaving the posts in place which would make less measuring and less mistakes or
2. cutting it half way down the posts and measuring everything fifty million times and weld in once
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post #18 of 109 (permalink) Old 12-10-2009, 01:32 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

I have been going through the two possibilities in my mind and have decided that it would be just easier to cut the old roof half way at the posts, do all the critical measurements, and weld at the posts on the new roof where they come together....have gotten some quotes of $750 and $300 for just the roof and unfortunately looking at doing some long traveling....but you know what when she is finished it will be worth it
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post #19 of 109 (permalink) Old 12-17-2009, 12:40 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

I found another boneyard that might have a replacement roof....discovered it off of *************************** LOVEfords - Ford Mercury Edsel Lincoln Articles, Data, Pictures, and Information in one of the forums....the place is called Baughman's Auto parts up in York,PA 717-846-3944....supposedly from the pics posted on that site there are 3 yards full of 30's cars/trucks/wagons all the way up to the 60's and more....he might have a replacement roof for me and is willing to cut it at the posts for $200 out the door....of course I would need to do the road trip from FL to PA and remove the glass...he is going to give me a call back tomorrow if they have something that isn't rotted out..he did mention that the stuff needs to go or it will be in auto heaven soon because of the rust
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post #20 of 109 (permalink) Old 12-19-2009, 05:39 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

Today was cowl removal day......took me about 4 hrs to take out all of the spot welds and definetly learned about patience tackling this puppy! Anyway the outer edges were rotted out around the hats and of course tons of leaves in my way....whoever owned the vehicle before me in the past sprayed some white silicon/rubber sealant up into the hats...it was caked on the bottom of the upper cowl when I removed it....was actually about 2 inches thick....now just need to clean it up and find some replacement outer edge cowl metal
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post #21 of 109 (permalink) Old 12-21-2009, 02:15 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

I discovered that there are no vendors out there that make falcon cowl patch panels....Why just boggles my mind? Anyway I am going to have either form in some fabbed sheetmetal and put in new hats or find a good donor/replacement from a parts car......also will have to find a driver's side fender apron as that is rotted out on the top
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post #22 of 109 (permalink) Old 12-22-2009, 05:30 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

Today I ended up taking out the emergency brake assembly.....prior owners were harsh on it and the wire broke plus it was spray painted that awful green dash color....contacted Unique Ford salvage here in Orlando and Donnie will get back with me to see if there are any good cowl repair patches and aprons from his parts cars
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post #23 of 109 (permalink) Old 12-29-2009, 11:26 AM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

I talked to someone who knew someone who knew someone and ended up finding a replacement roof.....the guy lives in TX and has a '64 wagon parts car....he has all the metal replacement parts that I need like the cowl, quarters, torque boxes....anyway he is going to put together a package deal for me and I will probably have it freighted here in the next 6 months....anyway back to the roof it is rust free and won't have the posts just the top inner structure/rib section with the roof skin...he is going to shoot some pics over in the next week and we'll go from there
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post #24 of 109 (permalink) Old 12-31-2009, 05:45 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

strolled on by the bodyshop again to see the progress on my other '65 falcon car....unfortunately not much new just some more dust on her....I have been a thorn in the owner's side to get him moving on this.....basically he is bouncing back and forth between my project and a '68 dodge dart...again the only thing done considerably has been the patch of the sunroof hole (can't even see it now)

Last edited by 65fordfalcon; 01-17-2010 at 07:25 PM.
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post #25 of 109 (permalink) Old 02-12-2010, 07:57 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

wanted to give you all an update since I haven't posted in awhile: anyway my main focus right now is getting the body back in shape....I tracked down someone who is going to cut out a good upper/lower cowl and will cut it out including the side apron cowl and door hinge....since I plan on replacing the rotted out cowl hats and damage on the driver's side this works out perfectly....the guy's name is Brian and he is out in CA....pros are getting rust free sheet metal to replace the rot but the con is the shipping charge...oh well gotta get r done! Here are some pics of the real bad metal that needs replacing on the driver's side
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post #26 of 109 (permalink) Old 02-14-2010, 05:29 AM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

here are some more pics of the rusted cowl area.....in the second picture note that I have taken the roof skin off as well
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post #27 of 109 (permalink) Old 02-14-2010, 11:57 AM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

Do you think I need to do a roof replacement on my wagon?
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post #28 of 109 (permalink) Old 02-20-2010, 10:50 AM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

Here is a picture of the original a/c that came with the car....I plan in the next couple of months to take it to Classic Auto Air here in Tampa and have it refurbished....it will probably take about 6-8 weeks to get done and they will charge me about $500....all I need is to provide a clutch core when I drop it off
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post #29 of 109 (permalink) Old 02-26-2010, 01:57 PM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

got my new rust free cowl in this AM from CA....I have a contact out there that has alot of the sheetmetal that I need for the wagon...it only took 3 days from CA to FL.....anyway he cut out the entire cowl including up to the door hinges and partly way down the side cowl apron
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post #30 of 109 (permalink) Old 03-10-2010, 10:26 AM Thread Starter
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Re: saving another '65 falcon 2 dr wagon!

Update:

Got a hold of my buddy, Brian out in CA and he is going to send me some more metal pieces to replace the rotted out sections of the car....he is shipping me new rust free torque boxes, transmission tunnel section, as well as firewall sheetmetal....all that for $400 (including shipping) not bad I thought and from CA to FL...he is the bomb when it comes to falcon parts!
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