BUILD THREAD For 1964 Falcon Sprint to Monte Carlo Rallye FIA spec'

Thanks Bruce,
I have really enjoyed tinkering around with this project, probably why its taken so long to build! Anyway its on the home straight now.

Dale Mathers from Coastline Automotive has built me an awesome original 9 inch Detroit locker diff and supplied some 31 spline axles etc, very happy with that.

I have also finished the engine (road version) and gearbox, Super T10.
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Fitted up the Hays clutch & pressure plate (same as 1964 original), every thing is ready to go in to the car.
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The Falcon T10 gearboxes had a different tail shaft housing to the mustang (otherwise the same) the shifter is mounted much more forward in a Falcon than a mustang.
Many mustang Falcon parts are not the same such as the clutch Z bar was specific to Falcon and 1964 is different to 1965 as are 6 cyl.
There have been so many considerations to build this car correctly to Ford, Holman Moody and Alan Mann Racing 1964 specs.

Holman Moody made a huge amount of changes to the car for entry into the Monte Carlo Rally of 1964, but the Falcon needed to remain looking as an OEM production car.
Ford had to comply with minimum production of 1000 Rallye Sprint cars so they offered an actual 1964 Falcon Rallye Sprint for 1964 (RPO) which included all of the Holman Moody parts that were fitted to the 1964 Monte Carlo Falcon Race cars. In turn these cars were actually classed as a Regular Production Option vehicle to meet the criteria for entry into the 1964 Monte Carlo Rally.
I recently managed to find an original 1964 Falcon Rallye Sprint hand book.
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What a find! all of the original part numbers too!

That booklet is great - to go with the Car well done Paul..

Thanks Roger,
A real gem there with all of the ford part numbers and also shows Holman Moody part numbers so I know what was made at Holman moody that replaced the Ford parts. Hugely useful.

The engine and gearbox is in the car now, still a few more parts to fit
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Here is a pic from the 1964 car
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Engine complete ready to fire.
I will connect the external oil cooler later, Radiator with a left inlet will also be fitted later

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Here is a pic of one of the original cars for 1964
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This car was fitted with Girling brakes, the others had Kelsey Hayes front Discs

I started to fit my diff together, measured the axles and checked the axle length and found the diff housing has been modified sometime in its life. The offset has been altered, so it has gone off to be corrected back to what it should be. After researching the diffs for these cars I have found the most likely diff housing used was a 1959 ford ranch wagon diff housing as this was one of the very few 9 inch diffs with 2 inch wide shoes on 11 inch back plates and drums (which is correct for FIA #1250). This model diff was also a perfect fit into a 63-65 Falcon or 64-66 Mustang.
The diff head was a Detroit locker 31 spline which I have now. So it all should come back soon correct and I can bolt it up.
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I was going to give my usual plaudits, then I saw the seat. Is that what they used? We can do a lot better for you Paul.

Paul, is the roll cage built to original specs or has it been made to suit MNZ rules?

Hi OF, The race seat is a USA Kirkey, the upholstery cover was not fitted yet, it is a new old stock seat and period correct for the car even though in 1964 they did not have race seats in these saloons, either factory buckets or a special touring seat was used. But I must have a compliant race seat to be eligible to race. I don't really want a modern looking seat. what seats do you have?
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Hi Allan, The roll cage must be Motorsport NZ homologated, and is, I have the log book now.
In 1964 these cars were actually raced without roll cages as were many saloons.
The roll cage is a bolt in and I have tried to keep it as period as possible whilst also complying to MSNZ regulations.

Cheers to all

By the way, with the roll cage in now, the rear seat back and carpets still have to go in, these are being made as I don't want to cut up the original parts.

Real progress Paul B, great to see the car this complete.

Hi Paul, the email I have for you has failed. I'm still on the one you have used previously.

Quote:

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Originally Posted by Paul B

I started to fit my diff together, measured the axles and checked the axle length and found the diff housing has been modified sometime in its life. The offset has been altered, so it has gone off to be corrected back to what it should be. After researching the diffs for these cars I have found the most likely diff housing used was a 1959 ford ranch wagon diff housing as this was one of the very few 9 inch diffs with 2 inch wide shoes on 11 inch back plates and drums (which is correct for FIA #1250). This model diff was also a perfect fit into a 63-65 Falcon or 64-66 Mustang.
The diff head was a Detroit locker 31 spline which I have now. So it all should come back soon correct and I can bolt it up.
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So my diff housing has been away getting rebuilt back to the original 59 Ford dimensions in order to keep the car correct.
The axle tubes needed to be cut off and replaced with the correct length
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new axle tubes welded on

On to the dash and gauges now. The original Monte Carlo Falcon of Graham Hill had the radio removed and a set of gauges and switches located in a custom panel. Graham Hill and Ian Walker had no Music to listen to in the 3500km rally in 1964.
Here is a pic of the dash
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And here is my effort so far, a bit more work required and some paint plus I would like a Smiths Oil gauge and Temp gauge
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I still need a few switches and will complete it this week
The last of my parts arrive from USA in a few weeks to finish the car, The upholstery, livery and diff is being finished soon I can hopefully drive it in 3-4 weeks.

Paul,
I was driving near home today and saw this beauty parked by a field. The nice elderly lady said it had been in the family since new in 1964.
One does not see a 1964 Ford Ranchero around here very often so I had to share this one.
(Note the smoky haze in the background from the fires near Laguna Seca, 200 miles north of us. )
With a more powerful engine I thought this would make a fine tow vehicle for you.

p.s. I always appreciate your inputs and admire your craftmanship and attention to detail.
Cheers, Ken.

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Nice Ranchero Ken, 1965 grill with 1964 side trim. Not sure if they came like that in 65.

On to the last bits of detail, finishing the dash gauges that the Monte Carlo Rally cars had, This was how the G Hill & I Walker car was set up, Each car was a little different. I still need to get the Gauges cleaned up and add labels
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The diff housing has all been rebuilt to how it should be, beautiful job and fits like a glove thanks to Tim at The Krysler Shop.
I have stripped it back and repainted the housing and fitted it into the car today together with the FIA 1250 Holman Moody brakes & drums.
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The diff head is a Detroit Locker, 31 spline nicely built by Coastline Automotive.
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The brake shoes are 2 inch and have 9 pads instead of the 2 long brake linings. Also a smaller Brake cylinder was used as fitted all as in FIA 1250 homologation.
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The Koni Classic shocks will go in as soon as they arrive from being re calibrated.

Got some more done last night,

Fitting the gauges, Nice set of Smiths UK, The G Hill car used the original Sprint steering wheel
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This is Bo's car #49 with different Grant steering wheel
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Also starting livery fit out the same as the Graham Hill car
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More excellent work PB, I'm hanging out to see that old girl run.