1962 Ford Falcon: Pro-Touring Lite

[neongreen]

Hi guys. I've been lurking here for a while, and draw a ton of inspiration from you guys and your builds so I figured I probably ought to share. I'll just give you the quick rundown because the full story is on my blog, ironhydroxide.blogspot.com

I bought Grace for $600 with no engine or transmission about a year and a half ago. This project is a Happy Graduation to ME! present. During Highschool and College I built a turbo ranger which was also my daily driver. It was fast, but only in a straight line, and made people start to pray hard by the time I shifted into fourth gear at 96 mph. I wanted to build a driver's car that had confident, direct feel in all aspects.

This car has a TCI mustang II and 4-link rear suspension, adjustable coilovers on all 4 corners, full disc brakes, 8.8 LSD with 3.73 gears, a t5 tranny, and....

A ford 2.3 turbo.

I find that my car doesn't quite fit in with any crowd, and I wouldn't have it any other way. Grace and I probably fit in here best, I really like the pro-touring nothing is impossible attitude.
That's a little bit of background, but if you want more, start here: http://ironhydroxide.blogspot.com/2013/04/no-smog-for-you.html

97139
My highschool/college project/DD

97140
Grace on the day I picked her up

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getting started with the blue wrench

97142
much better

97143
original suspension in it's proper place

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installing the good stuff

97145
much better

97146
Third world vise

97147
4-link brackets installed

97148
rear end reassembly

97149
On her own feet

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new bundle-o-snakes

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positioning engine

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building motor mounts

97153
heart transplant

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heart transplant pt. 2

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engine in place

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looks just right

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Subframe connectors


Well that's the quick and dirty of the past year and a half. I'll post links as I update my blog, since that's where all my real writing and details take place, though I'm certainly open to have discussion here as well.

[Gil]

97158
Very nice sleeper !
I like where you are going with it.
Will you keep the rat look rusty '"patina" ?
Gil

[Josh@Ridetech]

Cool project man!

[hectore3]

Very nice. I like more of these buck down builds.

[neongreen]

Very nice sleeper !
I like where you are going with it.
Will you keep the rat look rusty '"patina" ?
Gil

I plan to keep the patina, I figure the paint is good for at least another 15 years. No need to spend any unnecessary money ;)

[chevyz240]

Cool and differrent project! I like alternative engines. Not every car has to have a V8. Nice welds on the 4-link brackets! Nice patina also!

[Bryce]

cool project

[turboclevor]

Sub'd I have been searching for a falcon for this exact build I've got a burnt up svo mustang behind my shop for this

[xpander343]

The complete write-up on your blog is a pretty awesome read

[RIDES BY DESIGN]

interesting build...

[injcted]

Keep the updates coming. Cool build!

[nitroracer]

Unsuspecting four door with power and suspension upgrades - I like it.

[impala65maniac]

Cool build, very interesting.

[Munssey]

YES!!! I feel like i've built a version of this Falcon in my head every time I see one on CL for cheap!

Keep up the good work (and the updates)

[R32Jordie]

Nice to see more turbo cars on here.

[neongreen]

http://ironhydroxide.blogspot.com/2014/07/the-band-plays-some-song-about.html

Very minor update, finished up the subframe connector install.

[Munssey]

Good progress comes in bite size pieces some times!

[Mycarsmettle]

Pretty epic sleeper! Well thought out too.

[Dave B]

Wow, being the Ford guy that I am, I gotta say, this is pretty freaking sweet! I don't know how I missed it before, nice work!

[neongreen]

http://ironhydroxide.blogspot.com/2014/08/teach-me-how-to-dougie.html

transmission mount and random adventures

100826

[neongreen]

106671


No updates that I'm ready to share just yet other than this little teaser but in the meantime, Merry Christmas!



http://ironhydroxide.blogspot.com/2014/12/i-wouldnt-touch-him-with-thirty-nine.html

[no go nova]

Lets get this Falcon flying.

[neongreen]

Lets get this Falcon flying.

Don't worry, I'm still working on it! :)

[neongreen]

106692

Intake manifold is (almost) done! For more details and pics, the blog post is below.

http://ironhydroxide.blogspot.com/2014/12/she-was-built-with-brain-and-some.html

[85coupe50]

two more doors than I like but a cool car none the less. I like your use of the turbo 4 cyl. Keep it light and more than enough power to have some serious fun!

[nitroracer]

The blog posts are pretty good, thanks for sharing the build!

[neongreen]

two more doors than I like but a cool car none the less. I like your use of the turbo 4 cyl. Keep it light and more than enough power to have some serious fun!

Most cars I think look better with 2 doors, but this is one that I think the shape lends itself better to 4 doors. In any case, it's pretty similar. Thanks for the kind words, guys.

[neongreen]

http://ironhydroxide.blogspot.ca/2015/01/ill-be-what-i-am.html

Found the correct driveshaft spacer for ford explorer 8.8 axle and built seat brackets to put miata seats in my Falcon.

[Dave B]

Love the build! Enjoy Timmins, I'm glad I live in Southern Ontario.

[Justin@EntropyRad]

Keep it up..love the spaceships!

[neongreen]

http://ironhydroxide.blogspot.com/2015/03/all-these-buckets-of-rain.html

I got the radiator and intercooler in, and started fabbing pipes.

[MichaelUser]

For the record i like the build. I would seriously consider not hard mounting the intake hot side tube to the inner fender. When I was at my old job, we built intake systems for modern cars. We never hard mount intakes, tubes or intercoolers. We use these all the time: 110842


The engine moves too much and you don't want the silicone elbow to tear off or rip and they will. Plus you are putting all the stress on the clamp. It's only job should be to seal not hold things in place as well. 2.3L Lima Fords are very prone to vibrate (as you know) and the torque will rattle your teeth around. Also, I would add some trim seal around the cut out to insure the tube does not contact the inner fender. 110839 Good Luck.

[neongreen]

Excellent points Michael. If you look closely, the tube on the passenger side is actually the air intake to the turbo, I haven't made the hot intake tube yet.

[MichaelUser]

Excellent points Michael. If you look closely, the tube on the passenger side is actually the air intake to the turbo, I haven't made the hot intake tube yet.


Ok thanks. I was trying to tell but couldn't actually see. I will go back and check. That being said make sure to keep the filter covered with a pre-filter and go with the biggest filter possible. I am amazed that so many builder squeak in the littlest filter after it's all said and done. Turbo cars use a lot more air and shouldn't be hindered by the filter. Think of this: A diesel engine uses 7 times more air than a gas motor. For whatever that is worth. Keep up the good work.

[neongreen]

http://ironhydroxide.blogspot.com/2015/04/she-belongs-to-her-mother-and-state-of.html


Clutch, flywheel, slave cylinder bracket

[Bad Brad]

Sweet build! I'm planning on running this motor in my maverick!

[neongreen]

http://ironhydroxide.blogspot.com/2015/05/someday-you-will-die-somehow-and.html

workspace upgrade
fuel rail fabrication
building hose assembly tools
fuel system install




Sweet build! I'm planning on running this motor in my maverick!

I'm looking forward to seeing it!

[neongreen]

http://ironhydroxide.blogspot.com/2015/06/all-weve-got-right-now-is-this-box-of.html?m=1


Battery cables
Engine/trans plate

[neongreen]

http://ironhydroxide.blogspot.com/2015/06/take-your-economy-car-and-your-suitcase.html

Downpipe
Oil feed and drain
Cam swap
esslinger aux shaft swap
adjustable cam gear swap

[Centerforce]

Love this build concept and love your writing style. Abolutely first-rate on both accounts.

We're also sorry to hear that your prior experience with the Centerforce pressure plate didn't meet your expectation. I have to wonder if our Dual Friction system (http://www.centerforce.com/products/dual-friction-series) would have been what you're looking for on the Falcon, but you've already installed a different clutch so it's moot anyway. The important thing is that what's on the car matches what you want from the it; we always prefer that you prefer our clutches, but we also know that doesn't always happen. It doesn't change that we like your build.


http://ironhydroxide.blogspot.com/2015/06/take-your-economy-car-and-your-suitcase.html

Downpipe
Oil feed and drain
Cam swap
esslinger aux shaft swap
adjustable cam gear swap

Random trivia prompted by that Maserati replica: The Argentines love their Muscle Car-era straight sixes so much that the de facto national stock car series (Turismo Carretera) has run the same cars and chassis virtually unchanged for 40 years. It's actually pretty entertaining stuff if you understand Spanish, possibly moreso if you don't. Off the top of my head, I think they use derivations of the Falcon 221, the AMC 258, and GM's 250. The cars look like someone grabbed random parts tuner bits and bolted them onto a Late Model that had been bashed with an ugly stick (or an infield jersey barrier) consecutively for a few weeks.

Thanks/sorry for letting me interrupt your build thread. Carry on.

[neongreen]

Love this build concept and love your writing style. Abolutely first-rate on both accounts.

We're also sorry to hear that your prior experience with the Centerforce pressure plate didn't meet your expectation. I have to wonder if our Dual Friction system (http://www.centerforce.com/products/dual-friction-series) would have been what you're looking for on the Falcon, but you've already installed a different clutch so it's moot anyway. The important thing is that what's on the car matches what you want from the it; we always prefer that you prefer our clutches, but we also know that doesn't always happen. It doesn't change that we like your build.

Thanks/sorry for letting me interrupt your build thread. Carry on.

Thanks for the compliment! Perhaps I worded my evaluation of the centerforce clutch wrong. It really was an excellent clutch for it's purpose, I just think I was asking it to do too much. To expect a 9" clutch to have a light, LA traffic friendly pedal feel and still hold 400 lb-ft is probably an unrealistic expectation, hence my move away from the centerforce stg II. Perhaps a dual friction could do all that, I don't know since I've never used that product. I will say though, that if I didn't live in a high traffic area, I'd probably still be using a CF stg II.

Since I've already got you here, I wonder if you could provide a little troubleshooting advice for me regarding the clutch. As you know, I'm running a Fox body 5.0 bellhousing and fork. This is a cable setup which I've attempted to convert to hydraulic using a wilwood master and CNC push style slave mounted to the bellhousing via a bracket. When I depress the pedal it is really stiff, and feels like something is grating pr scraping as the fork moves forward. When I release the pedal, the fork and slave do not retract. I can press the pedal again with the same result. Fork moves forward, but will not retract after releasing the pedal. On the third depression of the pedal, the fork will move forward and then return when the pedal is released as you would normally expect. In order to get the fork to fully retract, it must be hit with a hammer repeatedly.

Additionaly, the other day I was degreeing my cam and when I went to rotate the engine and at a certain point it locked up. After moving it back and forth a bit, it finally came free. But even now when I rotate it, as the engine passes through the 160-150 BTDC it gets tight again, and when I force it through that range, I get a kind of scraping noise (maybe the clutch disk is shifting?). Any thoughts?

[Centerforce]

Thanks for the compliment! Perhaps I worded my evaluation of the centerforce clutch wrong. It really was an excellent clutch for it's purpose, I just think I was asking it to do too much. To expect a 9" clutch to have a light, LA traffic friendly pedal feel and still hold 400 lb-ft is probably an unrealistic expectation, hence my move away from the centerforce stg II. Perhaps a dual friction could do all that, I don't know since I've never used that product. I will say though, that if I didn't live in a high traffic area, I'd probably still be using a CF stg II.

Totally understandable. The Dual Friction and DYAD clutches we make both have excellent holding capacity without prompting leg-muscle workouts, but no worries. Centerforce is based in Rancho Santa Margarita so we know exactly what you mean.


Since I've already got you here, I wonder if you could provide a little troubleshooting advice for me regarding the clutch. As you know, I'm running a Fox body 5.0 bellhousing and fork. This is a cable setup which I've attempted to convert to hydraulic using a wilwood master and CNC push style slave mounted to the bellhousing via a bracket. When I depress the pedal it is really stiff, and feels like something is grating pr scraping as the fork moves forward. When I release the pedal, the fork and slave do not retract. I can press the pedal again with the same result. Fork moves forward, but will not retract after releasing the pedal. On the third depression of the pedal, the fork will move forward and then return when the pedal is released as you would normally expect. In order to get the fork to fully retract, it must be hit with a hammer repeatedly.

Additionaly, the other day I was degreeing my cam and when I went to rotate the engine and at a certain point it locked up. After moving it back and forth a bit, it finally came free. But even now when I rotate it, as the engine passes through the 160-150 BTDC it gets tight again, and when I force it through that range, I get a kind of scraping noise (maybe the clutch disk is shifting?). Any thoughts?

Let me run it by our tech guy, but is it possible that the fork isn't happy with the way the slave is moving it? Maybe something quietly got damaged during assembly? I'm sure you've already checked it over to make sure that's not the case, but we have a list of things to check from our Clutch Diagnostic Guide (http://media.centerforce.com/DiagGuide/DiagnosticGuide04DL.pdf):

1. Release linkage not properly adjusted or reset
2. Flywheel not surfaced before a new clutch installed
3. Flywheel surfaced improperly—incorrect flywheel step or cup dimension
4. Flywheel machined too thin or not manufactured to stock (OEM) specifications.
5. Release linkage worn or damaged
6. Hydraulics defective, leaking or air is trapped in hydraulic system
7. Release linkage cable stretched or damaged
8. Improper clutch fork geometry due to flywheel being too thin or bellhousing deeper than
stock
9. Improperly adjusted pivot ball
10.Clutch disc installed improperly (backwards)
11.Clutch disc hitting flywheel bolts
12.Clutch disc binding on transmission input shaft
13.Input shaft bent causing clutch disc runout
14.Pressure plate assembly and/or clutch disc bent or damaged
15.Clutch disc is too thick or has excessive marcel
16.Pressure plate has defective or damaged drive straps
17.Damaged, worn or improperly installed pivot bearing/bushing
18.Damaged or worn throw out bearing collar

[neongreen]

After doing a little testing and calling CNC about their slave cylinder, I think the < 2 degrees misalignment on the pushrod is causing the piston to bind in the bore of the slave cylinder.


http://ironhydroxide.blogspot.com/2015/06/i-hear-that-train-comin-its-rollin.html

[neongreen]

http://ironhydroxide.blogspot.com/2015/06/well-lampshades-on-fire-when-lights-go.html

Microwave Chimichangas, Lady Gaga's meat dress, and Satanists writing the terms and conditions of the Angry Birds app... Wait, am I a car blogger or a conspiracy therorist?

This is the final chapter of the clutch slave cylinder saga... I hope.

fuel tank leak check and paint

battery box mounted in trunk

finishing touches on intake manifold

brake lines finished

[Centerforce]

http://ironhydroxide.blogspot.com/2015/06/well-lampshades-on-fire-when-lights-go.html

Microwave Chimichangas, Lady Gaga's meat dress, and Satanists writing the terms and conditions of the Angry Birds app... Wait, am I a car blogger or a conspiracy therorist?

This is the final chapter of the clutch slave cylinder saga... I hope.

fuel tank leak check and paint

battery box mounted in trunk

finishing touches on intake manifold

brake lines finished

Flattered to be mentioned in the blog (even if we weren't a huge help), even more excited to see Red Green in there.

[neongreen]

http://ironhydroxide.blogspot.com/2015/07/life-aint-nothin-but-funny-funny-riddle.html

new firewall, trans tunnel, and PIZZA!

[neongreen]

http://ironhydroxide.blogspot.com/2015/07/man-i-aint-changed-but-i-know-i-aint.html

She's alive!!!

[neongreen]

http://ironhydroxide.blogspot.com/2015/07/he-just-smiled-and-gave-me-vegemite.html

Wiring harness and pissing off the neighbors.

[Jetfixr320]

The wiring looks great! Nosy busy body neighbors. Blah!

[LERM]

Congrats on the fire up. It will be cool to see pics of this one sideways dragging a cone.

You're not alone in your wiring lust. I bought a shrink tubing label printer when doing my buggies wiring... (NERD)

[Jetfixr320]

shrink tubing label printer

I need this!!

[neongreen]

http://ironhydroxide.blogspot.com/2015/08/the-path-to-heaven-runs-through-miles.html





exhaust, catch can, dipstick, power steering, engagement


116271

[rustomatic]

Nice progress--my own Falcon has been in kind of reverse progress as of late, and will probably remain an unmoved pile for some time. It's good to see yours moving, along with your blog. You've made a fine choice in pizza, by the way.

On the sound effects from your startup video: horror movie monster defeated by turbo?

[neongreen]

Nice progress--my own Falcon has been in kind of reverse progress as of late, and will probably remain an unmoved pile for some time. It's good to see yours moving, along with your blog. You've made a fine choice in pizza, by the way.

On the sound effects from your startup video: horror movie monster defeated by turbo?


Sorry to hear the Bird isn't flying!

Enough boost will defeat anything.

[timster]

Just read the whole thread. I'm digging it. Looking forward to seeing & reading more.

[neongreen]

Thanks, Tim!


http://ironhydroxide.blogspot.com/2015/09/im-like-one-eyed-cat-peepin-in-seafood.html

Sometimes I get distracted by side projects, like putting an RB20DET into a first-gen ranger.

https://static1.pt-content.com/images/pt/2015/09/IMG_20150709_104512-1.jpg

https://static1.pt-content.com/images/pt/2015/09/IMG_20150905_192006-1.jpg

[TAT]

Love the falcon, like how your doing something different also! Inspires me on nights like tonight when I can't sleep to come in the garage a finish up building my sons LIL red wagon as we call it. Basically a bad A$$ go cart redone on a wagon! All is custom built, need to rethink a few things. He's 10 and is pulls the front tires! Lol. Racing fuel doesn't help! Love build bud keep up the good work.

[Centerforce]

Thanks, Tim!


http://ironhydroxide.blogspot.com/2015/09/im-like-one-eyed-cat-peepin-in-seafood.html

Sometimes I get distracted by side projects, like putting an RB20DET into a first-gen ranger.

https://static1.pt-content.com/images/pt/2015/09/IMG_20150709_104512-1.jpg

https://static1.pt-content.com/images/pt/2015/09/IMG_20150905_192006-1.jpg

o_O





O_o






O_O

[neongreen]

Love the falcon, like how your doing something different also! Inspires me on nights like tonight when I can't sleep to come in the garage a finish up building my sons LIL red wagon as we call it. Basically a bad A$$ go cart redone on a wagon! All is custom built, need to rethink a few things. He's 10 and is pulls the front tires! Lol. Racing fuel doesn't help! Love build bud keep up the good work.

Sounds like a fun project! Powered by a Briggs and Stratton?

[neongreen]

http://ironhydroxide.blogspot.com/2015/09/every-night-they-rock-us-to-sleep.html

Got lights in the Falcon and took her for a drive.

The ranger became blood brothers with a Cherokee.

[neongreen]

http://ironhydroxide.blogspot.com/2015/09/soll-ichs-wirklich-machen-oder-lass-es.html


https://static1.pt-content.com/images/pt/2015/09/IMG_20150921_214532-1.jpg

Grace steps onto the scale, 2700 lbs, no interior. 55/45 F/R balance.


https://static1.pt-content.com/images/pt/2015/09/IMG_20150919_154447-1.jpg

Ranger gets an intercooler.

[neongreen]

http://ironhydroxide.blogspot.com/2015/10/i-looked-at-holes-in-my-jeans-and-i.html

No Falcon update today, just more RB20 Ranger updates and a story about cake.

https://static1.pt-content.com/images/pt/2015/10/IMG_20150926_160848-1.jpg

https://static1.pt-content.com/images/pt/2015/10/IMG_20150926_211415-1.jpg

https://static1.pt-content.com/images/pt/2015/10/IMG_20150922_162613-1.jpg

https://static1.pt-content.com/images/pt/2015/10/IMG_20151017_174457-1.jpg

[neongreen]

I'm still on a tangent, but I'm almost done with this minor distraction.
Got the injectors cleaned and flowed, and the ranger fuel system is up and running.

http://ironhydroxide.blogspot.com/2015/10/gather-up-your-jackets-move-it-to-exits.html

118593

[neongreen]

https://youtu.be/_q2yxzeZMPU

The Ranger is up and running, so maybe I can make a little progress on the Falcon now.

http://ironhydroxide.blogspot.com/2015/11/boogity-boogity-boogity-amen.html

[neongreen]

http://ironhydroxide.blogspot.com/2015/11/and-towels-are-oh-so-fluffy.html

Ok for real now, this is the last post about the Ranger project.

I got some good video. This thing is sufficiently quick and sounds amazing.


https://www.youtube.com/watch?v=9OSW5NOA1Rk


https://www.youtube.com/watch?v=CCx0QTVsH8o

[Jetfixr320]

Congrats. Looks like a fun ride.
Now back on the Falcon!

[chunger]

Looks like the trucks running good - but be careful blowing through the metering lights. That's a decent size ticket!

[neongreen]

http://ironhydroxide.blogspot.com/2016/01/ive-got-this-place-that-ive-filled-with.html

Built some new motor mount brackets so I could use a decent isolator. The 4-banger with no balance shafts makes for a lot of vibration and when it's mounted too rigidly, it's a miserable ride.
I also swapped out the dying t5 transmission for a rebuilt V8 Mustang t5, from Astro Performance warehouse.

[wfo guy]

Interesting!

[neongreen]

http://ironhydroxide.blogspot.com/2016/02/john-stockton-from-top-of-key.html

New 3 point seat belts and a transmission crossmember modification.

[nitroracer]

What car did your seats come from? They look comfy and a nice color to boot.

[neongreen]

What car did your seats come from? They look comfy and a nice color to boot.

Thanks! They are from an 06 Miata.

[Centerforce]

Cant say we're mad at the ranger because it's awesome, but it is good to see some progress on the Falc again!

[neongreen]

126943


Grace gets her pipes!

http://ironhydroxide.blogspot.com/2016/05/the-song-of-my-people.html

[neongreen]

https://ironhydroxide.blogspot.com/2016/05/creamy-peanut-butter-and-2-ply-cardboard.html

mounted temporary gauges and adjusted the coilovers

[neongreen]

127605

127606


http://ironhydroxide.blogspot.com/2016/05/the-drawer-of-jeremy.html


did a preliminary corner balance and finished up the transmission tunnel

[chunger]

Out of curiosity, what gauge metal did you use for the tranny tunnel? How did you shape it?

[neongreen]

Out of curiosity, what gauge metal did you use for the tranny tunnel? How did you shape it?

It's 16 gauge, which is significantly thicker than the OEM floorpan. I bent it with a sheet metal brake, using a method similar to what you see in figure 188.

127607

[neongreen]

http://ironhydroxide.blogspot.com/2016/07/i-gotta-say-im-huge-fan.html

set the pinion angle, modified megasquirt to control cooling fan, mounted cooling fan to shroud, and shroud to radiator, and found a lot of cool cars in my neighborhood.

[neongreen]

131165

http://ironhydroxide.blogspot.com/2016/08/man-who-run-behind-car-get-exhausted.html

finished up the exhaust, finally. except I still need to make 1/4 wave resonators, so I guess I've still got a bit to do.

[neongreen]

After my 4 month blogging hiatus, I'm back! And this time I'm talking about how to use a Flex Fuel sensor to run any mixture of e85 and gasoline, on the fly.

http://ironhydroxide.blogspot.com/2017/01/the-smell-of-drunken-hobos.html



136214
136215
136216

[neongreen]

Two new blog posts are up.


139796

http://ironhydroxide.blogspot.com/2017/04/clutch-masters-of-universe.html
Changed out the clutch master cylinder to get a better clutch feel, and reduce the pedal stroke.


139797

http://ironhydroxide.blogspot.com/2017/04/boxes-of-torque.html
Worked on stiffening the chassis. Ran into a lot of problems because 99-100% of round body Falcons were not ever intended to have torque boxes. I think some 1963 Sprint Convertibles had torque boxes, but I'm not sure on that. In any case, I fabbed my own torque boxes.

[neongreen]

140271

140272

Finished the second torque box. The whole point of building these things was to eliminate a resonant frequency issue. It turned out to be a success in my opinion.


http://ironhydroxide.blogspot.com/2017/05/boxes-of-torque-part-dos.html

[Boosted Falcon]

Great builds on both the Falcon and the Ranger. you have done what I have planned on my 64 Falcon other than the engine, I am installing a 2016 3.5 EcoBoost.
I was actually looking really hard at a 2.3 I4 EcoBoost. Nice work and look forward to updates.

[neongreen]

Thanks! The 3.5T is a hard charging engine! If I were starting over again, I think I'd use a different engine, either a JDM straight six, or a Duratec 4 banger. The old Lima is just too heavy and unrefined, and takes too much work to make over 300HP.

[neongreen]

http://ironhydroxide.blogspot.com/2017/05/the-froot-loops-of-safety.html

built a driveshaft loop, and finally, after four years, reinstalled the grille.

140331

[neongreen]

https://static1.pt-content.com/images/pt/2017/06/Flex2BFuel2BScript-1.png


http://ironhydroxide.blogspot.com/2017/06/return-of-hobo.html

Had some issues with the previous flex fuel sensor, had to get a new sensor.

I have a dyno appointment on Friday, so we will soon know if all this 4-cylinder turbo voodoo can make any power.

[Jetfixr320]

I was a few months behind on your post.

Great write ups. I need to build torque boxes for a 64 Falcon Wagon.

[neongreen]

Dyno day blog post!

http://ironhydroxide.blogspot.com/2017/06/the-day-of-reckoning.html

On 91 she made 321 HP / 308 lb-ft, which I'm very happy about. The e85 tune is a bit more complicated, I explain in the blog.

[neongreen]

I've been absent from the forum for about a year now, I suppose it's because I haven't done any work on the car.

As is usually the case, this is because life has been happening.

First: We moved across the country, and bought a house.
http://ironhydroxide.blogspot.com/2017/08/the-5-year-summer.html

Next: We remodeled that house.
http://ironhydroxide.blogspot.com/2018/01/insuring-domestic-tranquility.html

The whole house:
http://ironhydroxide.blogspot.com/2018/05/a-fine-place-to-do-business.html

And then I fought with the bulding inspector and nosy neighbors while preparing to build a garage. Oh yeah, we had a son as well:
http://ironhydroxide.blogspot.com/2018/07/if-it-pleases-crown.html

Finally, the garage has been built, and a driveway poured:
http://ironhydroxide.blogspot.com/2018/09/ow-my-bank-account.html


Once the garage is wired, and the wife is ok with the condition of the yard, I'll get back to the Falcon.

[Boosted Falcon]

Congratulations on a number of fronts, your child's birth, the new home, new shop and cross county move and solid HP numbers.

[neongreen]

Congratulations on a number of fronts, your child's birth, the new home, new shop and cross county move and solid HP numbers.

Thanks! It's been a heck of a year. A good one though. And this kid, while he takes up all my time he's so worth it. He's 4 months old now and making him laugh is just as fun as any of the car stuff I've done.

[neongreen]

164055



http://ironhydroxide.blogspot.com/2019/01/let-thy-cylinders-be-doubled.html

Pulled the engine and sold off all the parts. Going to try something new. Switching from Turbo I4 to NA, V8, ITB.



http://ironhydroxide.blogspot.com/2019/05/the-rushing-of-great-winds-or-creature.html
refreshing the engine.

[Boosted Falcon]

Fun

[cornfedbill]

Okay, that's a big change. I love the stack style fuel injection systems.

[neongreen]

I've been making slow but steady progress. I get a couple nights per week after the kid goes to sleep to go out to the freezing garage and chip away at the project. I'm hoping to get a first start over the Christmas break.


Engine mounting:

http://ironhydroxide.blogspot.com/2019/10/a-powerplant-and-tiny-drunken-man.html

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Exhaust:

http://ironhydroxide.blogspot.com/2019/10/why-pipe.html

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Engine removal, engine bay prep, and re-install:

http://ironhydroxide.blogspot.com/2019/12/the-dry-post-with-lots-of-pictures.html


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170525

[Boosted Falcon]

Great build, love the ITB's

[JayinMI]

And then I fought with the bulding inspector and nosy neighbors while preparing to build a garage. Oh yeah, we had a son as well:
http://ironhydroxide.blogspot.com/2018/07/if-it-pleases-crown.html



I just read this, and I agree 100%. I have a project truck that ocassionally (maybe 2 or 3 times a year, for about a week or less each time) comes out of the garage, usually so I can clean the garage up, or work on one of my other cars. Someone has called the cops on us several times for having my ugly truck (it's 2 different colors, isn't plated, insured or running) in our driveway.

The cops have actually been very cool about it, and usually tell me I have 2 weeks to move it back into the garage. I usually do it in a few days. Sometimes I leave it out longer than necessary just to piuss off whoever keeps calling the cops.

Recently, someone said we had "blight" in our front yard, and "construction materials" in the back. The "blight" was some overgrown weeds, and there were no construction materials. My GF is a caregiver for her handicapped brother, and can't always do yard work when it needs to be done. This made me decide on two things:

1. Once my truck runs and drives, I'm going to plate it and insure it and start it up every night with open exhaust at 9:45 until 9:59 and then leave it in the driveway because the cops said if it runs and is plated and insured, there is nothing they can do about it. lol

2. I'm changing the name of the truck to "Blight."

If the cops come out again, I'm going to tell them before they can come on my private property to look for whatever this person has complained about this time, I'm going to need that person's contact information. We don't even have an HOA.

Jay

[wfo guy]

I bought one of those 8 stack injectors. Make sure you remove the plenum cover. Mine was full of shavings and rust. I machined a bunch of stuff and turned the throttle bodies around. I had to use the newer small injectors to make that work. What year of front drive is on that engine?

[1965falconragtop]

I like the way that you did the motor it looks old school, with new reliably.
Dennis

[neongreen]

1. Once my truck runs and drives, I'm going to plate it and insure it and start it up every night with open exhaust at 9:45 until 9:59 and then leave it in the driveway because the cops said if it runs and is plated and insured, there is nothing they can do about it. lol

2. I'm changing the name of the truck to "Blight."

If the cops come out again, I'm going to tell them before they can come on my private property to look for whatever this person has complained about this time, I'm going to need that person's contact information. We don't even have an HOA.

Jay

Love it. I wrote "rust is not a crime" on the car cover back when that happened. My wife didn't love it, she likes to be a normal person, that's not my forte.

[neongreen]

I bought one of those 8 stack injectors. Make sure you remove the plenum cover. Mine was full of shavings and rust. I machined a bunch of stuff and turned the throttle bodies around. I had to use the newer small injectors to make that work. What year of front drive is on that engine?

Yeah I did take of the plenum cover while chasing some cruddy threads on the vacuum port, and there were a few shavings in it.

The front drive is from a 96 explorer. I'd prefer the look of some more compact and old-school brackets, but this should be really reliable. I hear this is the best accessory setup available on the SBF.

[neongreen]

Just finished building my engine wiring harness:

http://ironhydroxide.blogspot.com/2020/01/the-cream-will-rise-to-top-oohh-yeahhh.html


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[neongreen]

https://www.youtube.com/watch?v=TpiuSn08YCU

She fired right up, first try. Now I've come to find out that the engine was only running on 6 cylinders, but I've located the problem and should have it fixed shortly. I screwed up while configuring my ECU and fried two coils, I've now got the ECU figured out and new coils on the way. Felt really good to get it running on the first attempt though. Made me feel like I almost knew what I was doing.

More details for those who are interested:
https://ironhydroxide.blogspot.com/2020/01/three-hundred-sixty-six-days.html

[chunger]

Looks like it's coming along nicely!

Your intake was from SpeedMaster, if I recall. So far, how do you like it? Hopefully after you start driving it more this year you can give the us some feedback on it... it looks so tempting!

[neongreen]

Looks like it's coming along nicely!

Your intake was from SpeedMaster, if I recall. So far, how do you like it? Hopefully after you start driving it more this year you can give the us some feedback on it... it looks so tempting!

That's correct, it's a speedmaster intake. Impressions so far: it doesn't take much throttle input to rev. It's a little touchy, because the throttle bores are so big. And this may just be an issue with my throttle cable, but it's very easy for it to hang at 2% throttle which means it is revving to 1700 rpm or so. Ideally I'd run this intake with a DBW motor, but my ECU is in no way capable of that.

I'll keep you updated as I am able to drive it. It definitely sounds the part though 😁

[neongreen]

She's firing on all 8 now! Might have a ring seal issue though, I noticed one of the bores had a lot of taper when I had the engine apart.

http://ironhydroxide.blogspot.com/2020/01/i-got-my-ignition-coils-on-monday-which.html



https://youtu.be/u4OcM7zcOLE

[chunger]

Nice, sounds healthy!

[Boosted Falcon]

Congrats one getting her running, it sounds great.

[wfo guy]

If you mentioned this and I forgot, then I apologize but what are the brackets on the front drive for the ps pump and the ac compressor from?

[neongreen]

If you mentioned this and I forgot, then I apologize but what are the brackets on the front drive for the ps pump and the ac compressor from?

It's all stock Explorer stuff.

[wfo guy]

Thank you. I used an explorer engine before but the brackets on the left side were missing so I didn't recognize them. :)

[Bullitt67]

Neat project! I've got the same intake on a 363. Make sure you go through a balancing effort using one of those snail meters. Found it quite a challenge to get the linkage and all the throttles equalized.

There's a manual on Borla/TWN on doing this process FYI. My guess is your hanging throttle is due to this.

[neongreen]

Neat project! I've got the same intake on a 363. Make sure you go through a balancing effort using one of those snail meters. Found it quite a challenge to get the linkage and all the throttles equalized.

There's a manual on Borla/TWN on doing this process FYI. My guess is your hanging throttle is due to this.

I'm a little confused how you would do that on this intake... First, there is no vacuum port on these throttles, so how would you attach the meter? is there some other type of meter that is different from the standard vacuum gauge hooked up to a vacuum port? and second, the manifold has a 3/8 inch hole from each port leading to a common plenum, so wouldn't they all have the same vacuum anyway, so long as they are close?

Any info you can provide would be appreciated.

[Bullitt67]

I'm a little confused how you would do that on this intake... First, there is no vacuum port on these throttles, so how would you attach the meter? is there some other type of meter that is different from the standard vacuum gauge hooked up to a vacuum port? and second, the manifold has a 3/8 inch hole from each port leading to a common plenum, so wouldn't they all have the same vacuum anyway, so long as they are close?

Any info you can provide would be appreciated.

Here's the instruction sheet. https://www.borlainduction.com/media/Balancing_V8_throttles.pdf. You basically stick the device in each cylinder to check flow. Mine were way off. Some read high as 10, most in 4-6 range. Bigger numbers mean throttles are more open. The instructions don't cover what to do if a single throttle is higher than the others. What you do in that case is loosen the set screw on the aluminum collars that's between the throttles, then you can adjust it to be more closed. Then tighten screw down again. Takes some time, but essential to get it right.

On a side note, you're lucky your vacuum port worked! On mine the runners weren't drilled so no vacuum signal. Speedmaster wouldn't warranty (1 month past when I finally found issue). Was able to fix by drilling holes myself but still pissed that a company wouldn't warranty something so glaringly their fault.

[Boosted Falcon]

Yup just like the old SU carb syc gauge.

[neongreen]

Heres the latest. Fan shroud, patched trans tunnel, synced throttles checked brake pressure.

http://ironhydroxide.blogspot.com/2020/04/how-to-eat-elephant.html

[neongreen]

The interior is finally coming together. Put down MLV and carpet.

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https://ironhydroxide.blogspot.com/2020/11/fuzzies-underfoot.html

[neongreen]

http://ironhydroxide.blogspot.com/2021/04/variation-on-theme-by-tremec-t5-pocket.html

Trashed the pocket bearing in my T5, so I had it machined to accept a tapered roller bearing.


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186951

[chunger]

What do you think caused the failure?

[neongreen]

What do you think caused the failure?

My guess is that it was low on trans fluid, and it's also possible that the front of the input shaft was not properly supported by the pilot bearing. I think I had driven it too far into the crank.

In any case, the rebuild worked. I took my 3 year old out and he and the car had their first burnout.


https://www.youtube.com/watch?v=wDmUUsSP1Jc