1962 Ford Falcon: Pro-Touring Lite

[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/20...ken-hobos.html

[neongreen]

Two new blog posts are up.




http://ironhydroxide.blogspot.com/20...-universe.html
Changed out the clutch master cylinder to get a better clutch feel, and reduce the pedal stroke.




http://ironhydroxide.blogspot.com/20...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]

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/20...-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/20...of-safety.html

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

[neongreen]

http://ironhydroxide.blogspot.com/20...n-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/20...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/20...ar-summer.html

Next: We remodeled that house.
http://ironhydroxide.blogspot.com/20...anquility.html

The whole house:
http://ironhydroxide.blogspot.com/20...-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/20...ses-crown.html

Finally, the garage has been built, and a driveway poured:
http://ironhydroxide.blogspot.com/20...k-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]

http://ironhydroxide.blogspot.com/20...e-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/20...-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/20...unken-man.html








Exhaust:

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




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

http://ironhydroxide.blogspot.com/20...-pictures.html

[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/20...ses-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