Saving Granddad's Falcon

[Luva65wagon]

OK, just let me know. It will be no sweat since I have so much original wire, with bullet connectors, to make it from. Will be a simple plug and play.

That screw will need to get tightened some how to make things work right. Can't tell if it's an 8-32 or a 10-32 screw, but if it's an 8-32 it would be pretty simple to open the hole to a #21 drill and tap it with a 10-32 bottom tap to increase the screw size. The opening of the bracket would need to be increased a little too, but that's hopefully the resolve to this. If it's 10-32 already... a 10-32 helicoil would be my recommendation.

[dhbfaster]

Original wire with BULLET CONNECTORS?? Sold!
That would be awesome. Thanks much.

I'm not looking forward to the crick in my neck I'm going to getting upside down with my head under there...but it's going to be worth it I'm sure. While I'm under there, I can get those door light switches plugged too!

That screw is 8-32. I was thinking about tapping it to 10-32, but I don't really want to take the carb off to do it.
(by the way...pardon my noviceness...what size drill bit is a #21?) I do have a 10-32 tap.

The helicoil kits seems surprisingly expensive...and it seems like you have to drill it out anyway.
I didn't think I would have to open the bracket...I will double check that.

What do you think about the loctite form-a-thread stuff?
https://www.amazon.com/Loctite-442-2.../dp/B000WSEUII
If it's actually as good as they say, and it keeps me from taking the carb off, and if it keeps me from having to open the bracket which could make it off center of where it should be a bit...seems like it would be well worth the $25. I will get a new screw with fresh threads to go with it.
I have almost zero experience with all this stuff, but I do have a cheap (but not used much) tap and die kit...Harbor Freight.

[Luva65wagon]

Original wire with BULLET CONNECTORS?? Sold!
That would be awesome. Thanks much.

I'll work on it over the next couple days or so to get it sent to you next week.

I'm not looking forward to the crick in my neck I'm going to getting upside down with my head under there...but it's going to be worth it I'm sure. While I'm under there, I can get those door light switches plugged too!

Better you than me, but been there, done that enough times to already feel your pain (and it's not due to my own degenerative C5/C6!). Fortunately the door light harness just lays on the bottom of the dash "tray" and is a pretty easy install... relatively.

That screw is 8-32. I was thinking about tapping it to 10-32, but I don't really want to take the carb off to do it. (by the way...pardon my noviceness...what size drill bit is a #21?) I do have a 10-32 tap.

Drills come in 3 size designations. Fractional, Letter, and number. Number drills go from 1 all the way to very small, like #72 or something like that. Letters go from A-Z. To tap a 10-32 thread you use a #21 drill. I have about 50 of them, so if you hold off until I send the wire, I'll send you one for your own. And... you should use a 10-32 bottom tap, which will let you tap near to the "bottom" of a hole. Most taps are pointy on the leading end. Again, have many to spare.

The helicoil kits seems surprisingly expensive...and it seems like you have to drill it out anyway.
I didn't think I would have to open the bracket...I will double check that.

You'll need to open it up until a 10-32 screw will go through.

What do you think about the loctite form-a-thread stuff?
https://www.amazon.com/Loctite-442-2.../dp/B000WSEUII
If it's actually as good as they say, and it keeps me from taking the carb off, and if it keeps me from having to open the bracket which could make it off center of where it should be a bit...seems like it would be well worth the $25. I will get a new screw with fresh threads to go with it.

I considered suggesting something similar, but didn't think it was sufficiently successful to handle this task. I'd give it a 50/50 chance, whereas going to 10-32 (assuming there is room for a bigger screw, etc) or using a helicoil would be a 100% fix.

I have almost zero experience with all this stuff, but I do have a cheap (but not used much) tap and die kit...Harbor Freight.

Don't risk the H/F set on this. Be wary, at least. I use the heck out of their 3-piece step drills, and find them quite good, but other items, like this, I've used (I have all USA taps/dies) have been kind'a OK, at best. They seem to be going to a Good/Better/Best thing there now, so maybe they have Best stuff now, but haven't looked.

[dhbfaster]

It sounds like I better take the carb off to do the tapping of those threads.
I think that means I'm going to need a new gasket to go between the carb and the mount- and you made the one I have for me.
Any chance you have an extra piece of gasket material lying around so I can make another one while I'm at it?

The Harbor Freight tap and die set is definitely a super cheap one...but it did help me do some basic thread cleaning which is what I bought it for.
Most the HF stuff I have bought has been the so-so category, not in the good or best...but some parts do work and serve their purpose.

[Luva65wagon]

No doubt I do, Don. I'll let you know.

HF stuff is what it is. Some is quite good. They do have a fairly reasonable return policy too.

I'll get something mailed out to you first of the week.

[Luva65wagon]

This should get you going Don. I'll get it off to you on Monday unless you wanna come get it all. If there is a remote chance I happen to be near you tomorrow, I'll drop it off.

[dhbfaster]

Nice! I found a nice 10-32 screw at a lumber store in Burien...stuck it in there to see how much I’d have to open up that hole. Went right in...Screwed in perfectly and snugged right up.
I have no idea how the 8-32 was holding at all because it had to have been the wrong size...or maybe the falcon angels were watching And tapped it for me Friday night. It’s so solid though...I’m not asking any more questions...just taking this as a win. Then I worked on the sliding surface of that choke “banana”...works pretty smooth now. Carb done! On to the installation of the Pertronix, no need for the bit, tap or gasket material now.
(Meanwhile the starter is off and waiting for the new one. )
No need for a special trip on the wire if you can get it in the mail.
I’ll work on gettin the pertronix in the distributor and ready to go, and get the routing for the wire all set up.

[Luva65wagon]

on the carburetor!

I'll keep the wire with me today, just in case, but at the very least I'll mail it off.

[dhbfaster]

Well...Got the wire plugged in, got the starter installed, and adjusted the timing...it starts and runs. Didn’t get much chance to play with it yet though. Need to try it and see how it starts up cold.

[dhbfaster]

Problems with the choke cable now. On the inside of the dash, the metal Cable cover Slips inside the piece that holds it to the dash. I only had 15 min of falcon time today...anyone experienced this before? I thought about just sticking some gorilla glue on there, but I figure I should probably take it completely off the dash and get a good look at it. If anyone already knows a good solution to this...

[dhbfaster]

Well guys...I got the tires for Father’s Day. Went with the Milestar whitewalls and I have to say after all the surveys and looking at pics and old ads...I think I made the right choice. They look great. They’re about 3/4” bigger in diameter than the old tires and just slightly narrower. The ride is better too.
I got the choke cable all fixed up too. I cleaned it up, put some glue in where it was slipping and clamped it tight with the vice. So far so good.
it was a great falcon weekend! Now to finish tuning it up.



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[Luva65wagon]

Looks awesome Don. That picture should become your new thumbnail!

[dhbfaster]

Well I tried the new thumbnail pic from the iPad...it doesn’t take the new pic up for some reason.

So I got the timing advanced and the idle back closer to 500 when warm but it seems to idle a bit rough. (Pertronix installed) overall runs great, especially going up hills at lower rpm...which is much smoother and stronger now-but it just seems like a cylinder is missing now and then- especially noticeable at idle.

all the cable connections seem good. Now that I have a more powerful coil, should I check or change the gap on the plugs or change to a different plug?



DECCE68D-A24F-4B55-BD87-76DCC2478A30.jpg

[Luva65wagon]

When it's at idle in the garage, and warmed up, adjust the air/fuel mixture screw (base of the carburetor - not the idle screw, the other one) until the idle speed just stops increasing at that pedal position. Might be all you need to do.

[dkutz]

Just read all 42 pages of this post and oh boy so much info. Great car Don. Maybe some day our 62 Falcon will look that good.

Question on the tires...are your new ones closer to the stock diameter as the originals? The tires on ours are small and causes high rpm driving at highway speeds.