Thought I'd start my project build thread and update throughout the winter. I have a 57 Fairlane 500 2 door sedan that i am working on a 390 for. So far I am accumulating parts (mostly around drivetrain and suspension), then I will be working on the interior/exterior. More posts and pictures to come. Love the forum and the knowledge you have all shared.
Andy in MN
I love engine porn. :003:
Looking forward to watching this come together
Love build threads! Keep the pics coming.
Love those FE's. Keep the pics coming!
Good luck, I have found that a budget build is like a wet dream, it will get away from you.
Nothing better than a build thread with pics!
lol, budget build.........I quickly found out what that meant...........keep myself on a strict budget so my car doesn't have to be. What helped me a bunch was planning my projects so when I was saving $ for a particular project, I'd be working on other projects that were more time than money.
When making a plan, lead time is more important than ever. Many parts or services that were available in a week or 10 days are now 3 months out or more. Paint and upholstery have year or more waiting lists.
Welcome to the family. No matter what valley you need to cross or mountain of annoyances you may find in front of, there will be someone here who has already forged a way to get past them.
And this really is a family too. Enjoy!
And I LIKE having another FE guy in the fold... :003: There are couple of guys here who are FE gurus as well. And as Rich said..pics are GREAT!
As for a budget build...gee guys...he didn't say how BIG his budget was gonna be...maybe it's an insane one we (I) wish was available! :006:
The true definition of budget size is really "relative"! As many a wife has exclaimed in the past....The difference between men and boys is the price of their toys!
^
:003:
Have not updated in a while, but progress is occurring. The 390 is at the machine shop, cam bearings are being installed, deck is being slightly lowered, heads are getting cleaned up, along with a valve job. Compression should be at 9.5:1 when finished (since it was a truck engine, original was 8.2:1).
Have been spending many hours cleaning parts, now starting some painting on external parts, along with getting the starter and alternator ready for rebuild. it is 15 below zero here, great time to work on a car in the heated garage.
The parts are looking good. I see someone else has also figured out new car donuts make for good cheap rollers. I got my 16 inchers from Lincolns......5 bucks each. lol, I still use one for a spare.
Quote from: RICH MUISE on 2021-02-08 13:05
The parts are looking good. I see someone else has also figured out new car donuts make for good cheap rollers. I got my 16 inchers from Lincolns......5 bucks each. lol, I still use one for a spare.
I also have a 2001 Mustang GT with 9"/10.5" wheels and I had to go to the u pull it yard and grab 3 more donuts when I used to store it on the roller skates. Can't beat $7/each! Worked out great to put them on the 57 now.
Looks like what I'll be doing soon I hope...once I get the shop set up that is! Have I mentioned I HATE this move? I know where NOTHING is! Since i had the damn COVID...I didn't get to do the packing...so NOTHING is labeled! UGH! >:(
Been a while again. I have been busy sandblasting parts, painting, and got the engine back from the machine shop. I have the C6 torn down and need the rebuild kit to arrive. Yesterday I started the engine assembly and I now have the cam, crank, connecting rods and pistons installed. Just starting to get my springs on the heads so I can test fit and measure for connecting rods.
A few more engine build pics from 3/7/21
Engine porn, NICE! :snoopy2:
Looks like some heavy pitting in #2 though.... bawl
Those pics make me want to go out and buy another engine to rebuild! You must be getting pumped!!!
Quote from: CobraJoe on 2021-03-08 16:08
Engine porn, NICE! :snoopy2:
Ah yes...'da best kinda porn! :headbang:
Are all those brass looking pipe plugs threaded in all the way? They look like they are sticking out a fair bit more than the normal steel pipe plugs that I used. As long as they are in far enough that they stay tight, and don`t leak, I suppose the brass plugs would be OK, but take a close look at the plug in the front of the block, if it`s not in far enough, it can contact the timing chain, or cam gear. Did you make sure that there is a plug at the front end of the drivers side lifter gallery? Since it`s about 2" inside the front of the block, behind the distributor, it is not hard to overlook.
Quote from: CobraJoe on 2021-03-08 16:08
Engine porn, NICE! :snoopy2:
Looks like some heavy pitting in #2 though.... bawl
That look in Cylinder 2 is not very bad, mostly a shadow, plus some slight staining from sitting for years. Machine shop looked close and advised that their hone was good and not to bore out. Can't feel anything when running across it with fingernail, etc.
Quote from: lalessi1 on 2021-03-08 16:13
Those pics make me want to go out and buy another engine to rebuild! You must be getting pumped!!!
Getting really pumped. So nice to be assembling something instead of disassembly or cleaning. Enjoy the whole process, but nice change of pace.
Quote from: 59meteor on 2021-03-08 18:39
Are all those brass looking pipe plugs threaded in all the way? They look like they are sticking out a fair bit more than the normal steel pipe plugs that I used. As long as they are in far enough that they stay tight, and don`t leak, I suppose the brass plugs would be OK, but take a close look at the plug in the front of the block, if it`s not in far enough, it can contact the timing chain, or cam gear. Did you make sure that there is a plug at the front end of the drivers side lifter gallery? Since it`s about 2" inside the front of the block, behind the distributor, it is not hard to overlook.
They are. The brass plugs I have are taller than most of the steel ones that I have. They are well snugged in there and have some sealer on them also. I put steel in the oil galleys in the rear and they are set much farther in because of their height. Front plug has plenty of clearance for timing set. I did get the plug behind the distributor opening, mostly because I have seen from others how easy it is to miss. Plenty of fun to get that one in :)
I haven't updated in a while, life has gotten in the way....but some progress has been made.
I have test fitted the 390/C6 combo and modified the transmission crossmember where I needed to. Also was abe to work on header fitting. I purchased some Sanderson shorties for a 65-71 galaxie and they fit with minor modifications needed :burnout:.
Other big news is that last weekend I scored a used 57 Power Steering set up for only $100! In decent shape and cleaning up now. I also purchased a Sure Swift power brake set up this summer and my car is getting a bunch of the original upgrades. I will be adding a dual bowl master cylinder and disc brakes all around. Going with the Explorer rear brakes that are mentioned in here quite a bit and front discs off of a mid-70's ranchero.
While I do not post too often, teh info I have gained here and the encouragement are extremely valuable. Thanks guys!
I am glad you posted this. I would like to see how your project turns out, as I plan on running the same set-up in my Courier...390/C-6. with a tri-power. Thanks for updating...now when you post something i'll get a notice and can look at pics and ready your progress. :006:
Will do! I love the Couriers, my dad has had a 56 with a 460 since I was a little guy and many fun memories in that car.
Ah '56! I know where there are two of them waiting to be bought and put back on the road or to be melded together to make one.
We'd be interested if you have any details you could share via message.
Thanks
Andy
You have email... :006:
Another cool score this weekend, picked up a tri-power intake with matching carbs from the 61-63 Galaxies. I'll still start with the 4-barrel cast iron intake and carb, but eventually will have the tri-power in the 57. Gonna be really cool someday....
(http://www.mysmiley.net/imgs/smile/cool/cool0010.gif) (http://www.mysmiley.net/free-angel-smileys.php)
Quote from: akusler763 on 2021-10-05 13:46
Another cool score this weekend, picked up a tri-power intake with matching carbs from the 61-63 Galaxies. I'll still start with the 4-barrel cast iron intake and carb, but eventually will have the tri-power in the 57. Gonna be really cool someday....
EXCELLENT choice! Not that I am prejudiced or anything like that...but same thing I am putting on mine! :006:
Been quite a while since I updated on here, but progress has been made. the 390 and C6 are done, and I spent a lot of time test fitting them in the car to make the headers work. I scored some Sanderson headers made for a 65 Galaxie and had to modify to work around the 57 Steering box and also the passenger side frame/upper control arm. I then have disassembled the entire front suspension and have cleaned the frame, hoping to prime and paint it this weekend. Dash is out of the car so it can be cleaned up. I also picked up Explorer rear discs and those will be getting added once I get to the rear suspension and 9". Although I don't post here often, I check in almost everyday to see what folks have going on and get nuggets of advice. I'll throw some pics up here.
Sure wish I had a lift when I was doing mine!! Nice progress, thanks for the update.
HEY!!! Have you been rummaging around in my shop? Let's see..390-check...C-6-double check...406 tri-power-triple check!
Seriously though...keep posting...and pics. Looks good. I can't wait to get back on mine.
Since you have a Fairlane that the OEM 9" housing would have been small bearing. If yours is small bearing, the Crown Vic/Grand Marquis rear disc will be a bolt on.
Quote from: RICH MUISE on 2022-02-23 10:04
Sure wish I had a lift when I was doing mine!! Nice progress, thanks for the update.
Best tool I have in the shop, a real life saver
Quote from: gasman826 on 2022-02-23 11:11
Since you have a Fairlane that the OEM 9" housing would have been small bearing. If yours is small bearing, the Crown Vic/Grand Marquis rear disc will be a bolt on.
It is definitely a Fairlane and looks to be the original. Would the Crown Vic/Grand Marquis be a better setup than the 95-02 Explorer set up that I have seen posted in here? From what I could see in the article that was close to a bolt on. Because I haven't gotten into the rear end yet I haven't looked at how the Explorer set up will go.
Quote from: akusler763 on 2022-02-23 11:20
Best tool I have in the shop, a real life saver
^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
Oh YEA! :003:
Explorer rear disc is a direct bolt on for Big Bear 9". The CV rear disc is a direct bolt on for Small Bearing 9". The Explorer caliper holder to axle flanges hole pattern is different and will need modification. The bearing OD is larger on the Big Bearing so the Explorer caliper holder will NOT support the small bearing without some sort of adapter. An EBay seller offers Small Bearing spacers: https://www.ebay.com/itm/373913991550?ViewItem=&item=373913991550&vxp=mtr
If you are handy, there is no reason you couldn't make a set of spacers.
Hoist...the most valuable tool ever!!!! I had the engineers design trusses to meet zoning building codes but had to accommodate the height of a hoist. It is so close that the hoist touches the ceiling.
If I had room for a second hoist or if I had no hoist at all, I would seriously consider one of these portable single post hoists. There is no installation. When not in use, it can be wheeled over to the corner. If doing body work, the door can be wide open and the entire side is unobstructed. The down side would be the underside is obstructed for transmission removal. Unfortunately, there is no perfect hoist.
https://www.northerntool.com/shop/tools/product_200715977_200715977?cm_mmc=Google-pla&utm_source=Google_PLA&utm_medium=Automotive%20%3E%20Automotive%20Lifts%20%3E%20Single-Post%20Lifts&utm_campaign=Tuxedo&utm_content=71518&gclid=EAIaIQobChMImfjPh7GW9gIVkfLjBx2pOAn4EAQYBSABEgIMUfD_BwE&gclsrc=aw.ds
I'm sure you just set the carbs on backwards for the picture :003:
No, the carbs are correct........I think it's the intake that's backwards. :003:
Quote from: RICH MUISE on 2022-02-24 10:56
No, the carbs are correct........I think it's the intake that's backwards. :003:
Ah Rich...funny!!! Being a
Sam
Adam is funny! Especially from you! :003:
Quote from: RICH MUISE on 2022-02-24 10:56
No, the carbs are correct........I think it's the intake that's backwards. :003:
Thats a good one :003:
They are correct. The linkage was on the passenger side on both the Galaxie and Thunderbird tri's.
Wish me luck, hoping to spray the frame with primer and top coat this weekend. Need to clean the shop as much as I can, and get set up. Going to be 30 degrees here which is warm for MN, so need to run the furnace while also having the bottom of the door open and a fan blowing fumes out. Really wish I had gotten to this before winter so I could have sprayed either outdoors or with the door wide open.
Andy
Do you have any shot of the Sanderson headers in the car? I have the FPA headers on my 428CJ FE powered 59 2 door sedan, they fit the engine and car great, although I did have to modify my clutch linkage slightly to work with the headers. I did not have to modify my transmission crossmember at all, I modified the original trans mount to work with the toploader 4 speed, and the FPA headers allow the exhaust pipes to be routed above the trans crossmember, like OE. Concerning rear brakes, not sure if the Explorer drum brakes use the same axle end bolt pattern as the discs, but on my 59, I elected to use early explorer drum brakes, which are 10" x 2 1/2", compared to the factory 11" x 1 3/4". So, although the diameter of the Explorer drum brakes is an inch smaller, the extra width actually give a bit more swept area. And the smaller diameter drums makes taking the larger tires much easier. Anyhow, the Explorer backing plate pattern was different than either the old style large, or small bearing 57-59s. Since I wanted to use 31 spline axles, and narrow the rear axle housing slightly, to make the 275/60R15s have a little more clearance, I ordered custom length axles, and had my buddy weld on the Explorer/ "late model Torino" housing ends while he was narrowing the housing. So I believe that the 57 large and small bearing housing ends are different from , at least the drum brake Explorer.
Early and late big bearing bolt patterns are slightly different. The OD and ID of the bearing is the same and can be interchanged. The Explorer caliper frame will bolt to Early Big Bearing but a couple of the holes will need modification. I bolted two holes with an old bearing race aligning the axle and caliper frame. Drilled out the other two holes.
Frame painting went relatively well. I was able to get it close to bare metal on 95% of the frame,painted the inside of the frame with rust converter paint, then primed the frame with Eastwood Rust Encapsulator Platinum. After an overnight drying I sprayed 2 coats of Eastwood Extreme Chassis Black Satin. Looks nice, but a few spots have a different gloss sheen. Hoping it cures away, or else I'll likely not care since it is under the car :burnout:
Once again the 2 post lift made doing this solo much easier thank if I had to flip the frame on my own.
Andy
Quote from: 59meteor on 2022-02-25 17:12
Do you have any shot of the Sanderson headers in the car? I have the FPA headers on my 428CJ FE powered 59 2 door sedan, they fit the engine and car great, although I did have to modify my clutch linkage slightly to work with the headers. I did not have to modify my transmission crossmember at all, I modified the original trans mount to work with the toploader 4 speed, and the FPA headers allow the exhaust pipes to be routed above the trans crossmember, like OE. Concerning rear brakes, not sure if the Explorer drum brakes use the same axle end bolt pattern as the discs, but on my 59, I elected to use early explorer drum brakes, which are 10" x 2 1/2", compared to the factory 11" x 1 3/4". So, although the diameter of the Explorer drum brakes is an inch smaller, the extra width actually give a bit more swept area. And the smaller diameter drums makes taking the larger tires much easier. Anyhow, the Explorer backing plate pattern was different than either the old style large, or small bearing 57-59s. Since I wanted to use 31 spline axles, and narrow the rear axle housing slightly, to make the 275/60R15s have a little more clearance, I ordered custom length axles, and had my buddy weld on the Explorer/ "late model Torino" housing ends while he was narrowing the housing. So I believe that the 57 large and small bearing housing ends are different from , at least the drum brake Explorer.
I do not have any pics of the headers in the car, but since I start reassembly I'll post some. The passenger header was very close to the frame, so we notched the frame and welded in a piece of 1/4 channel steel so that the flange and collector can have more space. I also had to trip the upper control arm of some excess, and the Steering box.
I did modify my transmission crossmember for the C6, notching for the pan. I could have moved it farther back on the frame and drilled new hole for it, but decided notch and weld was easier than that. Once I am setting the engine and transmission back on the frame I'll take a few pics of what I did, maybe post those in the Transmission swap section.
The frame looks really nice. You did what appears to be a very fine job! Congrats! Good pics...keep them coming as you progress. :006:
Man....... that's down to bare bones! I like the color of the Eastwood middle coat.lol.....I would have been tempted to leave it at that. Love following build threads...as Hugh said, keep 'em coming.
beautiful work on the chassis. As has been said so often it's really annoying stripping a 57 to this point, but once it's down to that and the first parts are getting coated, that must be a superb feeling !
Quote from: RICH MUISE on 2022-02-28 18:53
Man....... that's down to bare bones! I like the color of the Eastwood middle coat.lol.....I would have been tempted to leave it at that. Love following build threads...as Hugh said, keep 'em coming.
The silver did look really cool, I was tempted to keep it that way, but decided it would get dirty on the road, plus I already purchased the black.
The most enjoyable step of the rebuild. Its the first step that feels like you're moving forward.
More progress. I was able to get most of the front suspension in this weekend (press in bushings, install control arms, Ball joints, springs). Currently resting on the old spindles/drums as my disc brake spindles are not ready quite yet. Notice the 2x4 center link so I can roll it :003: Rear end and leaf springs went in as is so I can roll it and test fit driveline, I'll pull again soon to strip and paint it.
I have also been spending a lot of time on the dash, decided to make it look one piece. A lot of work to fill and blend the seam for the end wings, not sure it was worth it, but looks nice. Have also been sanding all of the rust off of the interior steel trim so I can prime it. Amazing how a 65 year old piece of trim that was out in the weather for almost 40 years can come back with some elbow grease.
Thanks for listening guys,
Andy
I like the dash...had been thinking off and on about doing same. Seeing yours...makes me think about it again. :003:
That's a hard area to get into to sand........as you now know. I started out with a similar idea then as usual got carried away.
Frame is looking great.
I missed the primered dash pic the first time....looks great Andy!
Last night I was able to get the engine and transmission permanently joined and mounted in the car! Feels very good to see things coming together. Also here is a picture of some of what I am having to sand on some of the interior trim. Next week I get to roll the chassis out and clean up the underside of the body, wish me luck...
Andy
Looking good. The trim looks like it is in pretty good shape too. Lucky you! Progress is always a pleasant feeling!
It's been a while since I posted but progress is happening. I just finished completing the underbody work, painting the underhood sheetmetal, and cleaning/protecting the interior. I ended up replacing a portion of the passenger front floorboard, and having to refabricate portions of 6 floor braces. I also fabricated some small patches in the trunk. I have started with insulation panels. Yesterday I swapped the body (mounted on the rotisserie) for the chassis in my shop and will be doing engine break in during the next few weeks. Lots of other small items accomplished and am doing my best to be driving this summer. Thanks for all the info guys, love reading the posts.
Andy
Looking really good, Andy......nice thorough job on that underside. Feels good I bet to see progress!!!! What model Fairlane is it?
Very impressive, wish I had room for a lift and rotisserie back when I built mine.
Quote from: RICH MUISE on 2023-01-16 12:11What model Fairlane is it?
It is a 500 Club Sedan (64B)
Quote from: 57chero on 2023-01-16 12:21Very impressive, wish I had room for a lift and rotisserie back when I built mine.
I purposely built the shop (in 2019) tall enough for a lift. It was well worth it. I picked up the start of the rotisserie that someone had made on Craigslist this summer and had to fabricate the brackets and rotating assembly. It is a wonderful tool to use, makes things so nice to have in front of you.
I was able to test run/break in my engine this weekend, verify transmission shifting, etc. I don't think I can post a video here, and nothing to exciting to see. But here are a couple of pictures, one getting it ready (see my fancy core support brackets) and also one overhead when it was running.
Things went great, once we adjusted the timing a bit ran like a top. Great oil pressure, good temperature, etc.
Moving onto Brake lines and fuel line before switching back to a little remaining work on the body before I mate the body and frame together again.
Also got to go purchase fabric for door panels this weekend and starting that planning in my mind.
Andy
Makes ya' feel good to HEAR progress yes?! Congrats!
Working on a rotisserie makes the job come out so much better and makes work a hell of a lot easier; nicely done!
Been a while since my last update, but I have been working almost everyday on it. Trying to be on the road for a show in late June.
Brake lines, fuel line, brakes, and gas tank have all been installed. Still running down some brake issues but nothing I can't solve. I have front discs from a 1984 Grand Marquis and rears from a late 90's Explorer. Been working on sound deadened inside, seat installs, and replacing rocker panels. Exhaust is in and sounds great. I also used the solid linkage from a 1958 for wipers and modified an electric motor from a Mazda pickup mounted inside. This led to having to modify the defrost ducting a bit, but should be great to have electric and no more cables! I'll throw some pictures up for folks.
Also, I definitely understand that my thread title is misleading as this is not the budget build I thought it would be :005:
One other bit of fun has been the install of the window whiskers and side glass replacement, about 50% done there.
Thanks for all the help and encouragement,
Andy
Very impressive!! Tell us about the seats....I'm really liking that back one. Yeah, I did the hard arm wiper, but never thought about/realized a '58 had them, so I went the hard way, and also ran into the need to split the defrost plenum. Inside wiper motor............making me think you have plans to clean up the cowl??
Rich - The seats are out of a 2001 Pontiwreck Grand Prix at the local U-Pull it. When I got the car the seats were just rusty frames/springs and I decided I did not want to go through the pain of cleaning and re-upholstering them, plus I don't love the bouncy bench seats. I looked at the way our floors are (mostly flat) and the height off the floor we'd need and spent a few hours looking for some front buckets I could modify. I found this Grand Prix with seats that had no tears, no stains, or smoky smell and the backseat was only about 6" narrower than ours. I remade the transom they sit on out of wood and was able to insert the GP retainer assembly. They are taller than ours with the headrests and I'll be customizing by package tray for speakers and the seat height. I also plan to find a a way to mount the 57 seat emblem in the center at some point to tie into the rest of the car, pls Ford crests are cool.
As for the cowl, no plans to change the set up right now, putting the wiper inside on the center of the firewall was just the best way to utilize the 58 linkage since that is where they had the vacuum motor. For a switch I grabbed one from a late 80's F150 as anything newer have the wiper controls on the turn signal arm or somewhere on the column. I just got the linkage and wiper motor mounted over the weekend, electrical is still a work in progress.
Everything looks very Very VERY nice! I especially like the work done on the undercarriage. Absolutely beautiful!
Good work! :003:
X2! Absolutely beautiful.
Thanks everyone. The knowledge on here and the encouragement help keep me going.
Andy
Andy...there is a possibility that I will be in Minneapolis later this summer. If I am, I'd love to se your handiwork in person. Sure is looking sweet!
Quote from: mustang6984 on 2023-05-03 00:14Andy...there is a possibility that I will be in Minneapolis later this summer. If I am, I'd love to se your handiwork in person. Sure is looking sweet!
Sounds great if we could work that out.
More progress in the last few days, Rocker panel replacement is done, and now I am onto painting them to try and match the patina on the rest of the car. Wiper install was tested and brakes are now functioning as they should. I've test run it again a few times and also began painting interior steel trim.
hey guys, been very busy and haven't updated, but I finally took it for initial shakedown drive this weekend! Put about 20 miles on. I have some minor tweaks to make and going to try and make some more drives this week. I don't have any new pictures right now, but I'll try to get some and share with you all.
Andy
:icon_super:
Awesome!! Bring on the pics! Congrats!
That is a great feeling to finally be able to drive a project!!!!
Still not great at getting pictures, but brought it to my first show on Saturday and got one with my daughter and I. Running good for me, have a few minor tweaks but I am glad I have put 150+ miles on in the first week.
Andy
Hey! It is running! Great accomplishment!
Did you guys think to steal that Mustang? LOL!!! :003: