VanMergence - 67 Falcon Van

It has been quite a while and I am finally at a point to tear back into the Van and get to the unfinished things. A brief catch-up: Engine, front suspension, fuel tank, and brakes were all replaced. Front brakes updated to discs, 3 point seat belts installed.


The van has been in running/driving condition but has been in storage for a few years. I have started it up and driven it very seldom, just enough to keep anything from seizing up. I purchased a house last fall that has a decent size garage. I finally got the van out of storage and set up here to start tackling the remaining items, the largest being the body work. I just picked up a '91 AOD out of a mustang, Ill be swapping it in place of the C4 currently in there. Jeff sez "there's no drive like overdrive".

I installed some stock bumpers I acquired a couple of years ago to see if I like the look. I'll keep you posted.

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Be sure to post some pics of your work Brian. These days I think we'd all like to watch if we can't come and help.

Yippee! I like the bumpers.

I made the first steps by stripping the old interior. It was a quick thrown together interior the PO did to get it down the road, it worked for a bit but I always knew it had to be pulled. I discovered more rust than I anticipated, the spots I am concerned with fixing are the roof supports. It will be covered by a headliner but I want to make a real fix.

I also have door hinge pins to deal with as my rear right door hinges are both broken :WHATTHE:. I have ordered some replacements but I am having a hard time getting the old ones out. I have been soaking them in PB blaster for a couple of days to no avail. I am going to apply some heat tomorrow and see where it leads me.

I decided I needed to dust off my welding chops so I took some old bed frames left behind and built a storage shelf for all of my parts. next will be some floor patching then moving on to the roof.

the last picture is the 91 AOD i picked up that I need to clean. I am going to drain it, clean the pan, and change the filter then cross my fingers. They gave me the cross member with it so i am going to try and use it for the swap.
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Wow Brian, that's an odd place to have that much rust. I hope it's not too bad when you get it descaled a bit.

Looking at these pictures bring me back a few years when I drove, and worked on, my '56 F100 panel. I got so fed up with my rear door I just welded them together and made a lift-back. But it looks like you have broken pins in the hinges? If so, then yes - heat will likely help. Had similar issues on mine and that's how I got them to come out. Though I never really got the interior on my panel what I considered show quality, it was a fun vehicle. I gave most of the pics of it away when I sold it (pre-digital), but when he traded it in, the dealer made a couple videos. I may have shared them here before, but they're interesting (to me anyway), so enjoy...

https://youtu.be/8NgnQvwpLcM

https://youtu.be/EtD323W1ZW4

I looked at a few panel/delivery trucks before I got this van. I do like them quite a bit, nice professional work on that one. Signature Roger sound system. "A number 7, above driver" :D. That lift hatch is super cool, I always worry about the extra pressure wearing out the hinge but then again I have an 85 wagon and the hatch still works fine after 280k.

Yes, the hinge pins are broken for sure. I'll try some gentle heat at first and work up. On the van forum it looks pretty common to have them frozen. If I get fed up with them I might move to a different method, maybe a roll up security door like a Starbucks at the mall.

Ill be stripping the roof this weekend to see what is under there. It will never be a show van but I think I can get it to look decent and work well. Again, it will be covered by a headliner eventually.

It was a challenge doing that hatchback. I did a center-only hinge, about 6" wide, which supported the door OK (always planned to lighten the doors, but never got to it), but man I hit my noggin on that thing more times than I care to remember. Who am I?

Please keep us updated as you go. Some activity here is nice to see.

Seeing this post bring back old memories .Back in my hippy days I drove a panel van.It had the shag carpete,Wood paneling and the loudest stereo I could buy.Loved the hell out of it. Drove it for almost three years till a old man pushed the rear bumper all the way up to the rear wheels.I went with the AOD in my last couple cars. Great for cruising and gas milage.

Check out those two video links four post before this one. These are my old panel truck, which I drove over 25 years.