The project begins
This old wagon is a XP Falcon deluxe station wagon, white/blue int, 200ci/3sp auto basic car. Was picked it up as an unfinished project in 2005, but due to all the other projects Warren had going on it had been sitting in storage for ages . Eventually when it was time to start the project, it was brought to his home garage to begin the tear-down phase.
The plan for this vehicle is to replace his daily driver XP wagon whilst not being without wheels (hence not just restoring the one he already had).
The xp wagon will become Ford BA/Territory – Icon Blue, roof will be XP Arctic White and blue standard interior. It will look as stock as possible.
Final phase Ready to register.......what do you all think? Would you prefer a new ford station wagon or this old overhauled classic?
Plenty of work to do on the XP Wagon
Getting ready to strip out the interior of the wagon to get ready for plastic bead blasting.
XP Wagon at delivery to home
These are photos are of the wagon whilst on delivery to home. Note the patches of grey primer were done by Warren as it'd been rubbed back to metal in these spots & he wanted to cover during storage.
Ford XE donor car for project.
Warren had an XE station wagon which was stripped of all it's gear engine/auto/rear end/brakes/wheels/rad etc which will all be used to upgrade the XP under the skin. The XE was bought real cheap (rusty body) but the engine etc has all been rebuilt in the last few years and it runs brilliantly (at least it did).
The before shot of the engine bay of the xp wagon
The old Ford xp wagon engine bay that will be transformed once the old 200 pursuit & automatic is removed.
Old 200 pursuit 6cylinder engine & auto out!
Engine and auto out all together. The best way to remove an xp engine and automatic or manual is to remove them together. There is not too much to it. Remove the bonnet, radiator and tailshaft.
Empty xp engine bay.
The empty engine bay ready to be resurrected. The before shot!
XE Donor car engine bay.
The replacement engine ready to be removed from the old XE donor car.
XE engine out!
The XE engine is out ready to be cleaned up and painted before it is transplanted back into the xp wagon. This is the alloy-head 4.1 etc to be used in the XP.
XE Donor car leaves the building
Wazza kept all the pollution gear from the XE so far, including the charcoal cannister. Even though it looks like a piece of ****, the XE was a sweet driver, was purchased in Frankston & drove it home to Geelong and couldn't beleive my luck. He no probs with using the pollution gear as it stands. Only modification Wazza made to the engine is removing the power-steering pump & the air-conditioning compressor. Wazza got the alternator mount brackets for a non-airconditioned car.
Notice the lack of wheels. He removed the front stubs/rotors/calipers and had the rear end shortened to suit the XP. Nicer ratio, new bearings & bigger brakes both front & rear.
XE engine painted.
The XE engine has been cleaned up and painted, ready to go back in. Looking so much better compared to when it was removed. The donor car only had about 80,000 kms on the reconditioned motor & auto and drove beautifully.
Ready for Carstrip PL to bead blast
Plastic bead blasting of the entire wagon for around $1000. Does a great job and saves plenty of elbow grease.
Does it remove rust? Wazza was quoted that it wouldn't remove rust, only paint. But when the car came back, most of the surface rust on the underbody was gone, and it'd been blasted through in a couple tiny rusty spots here & there. There was a spot with some rust pitting, & that was cleaned out with just the pitted steel remaining. Wazza says it'd remove "easy" rust if that makes any sense.
All the seats and fuel tank out.
Straight into stripping out the interior. Floor etc seems to be in very good condition. Looking at the floors looks like they've been treated before. The majority of the interior is out so all the metal on the interior can be plastic bead blasted.
Back in Wazza's garage
The carstrip company finished the paint stripping process back to bare metal. The wagon was picked up from Carstrip in Campbellfield. Wazza was very pleased with the job they did on it. The only drama was trying to beat the rain home to Geelong!
Back to bare metal
The plastic blasting is so gentle, it doesn't fully remove traces of the production line markings. The next process involves getting the metal covered as quick as possible to avoid any moisture getting into the metal.
The bead blasting is fantastic! & couldn't be happier. However, he spent a hell of a lot of time with the pan-brush & vacuum cleaner as the stuff gets everywhere. Then when it was rolled 90degrees, found it was all inside the frame rails etc. He had to blast air through every crevice to get the stuff out & still found more. The results on the metal are bloody good though!
Wazza's backyard rotisserie
The rotisserie was something drawn up by Wazza. Not only does he rebuild cars he does engineering design. It was built with the help of his father-in-law. Only took a weekend to put together, but he had some plates profile cut beforehand. The steel cost around $100 but he got looked after by some guys at an affiliated fabricators shop from work, so I’d imagine it might cost a bit more than that.
Car is sitting up on the rotisserie but havent yet turned it. As you could image Wazza was stressing at the thought of spinning his pride & joy on his home made rotisserie. The next stage is turning it so he could finish the epoxy primer coat.
Painting on the rotisserie
Wazza was feeling pretty happy with myself. By building a rotisserie & having the car bead blasted, I thinks he has saved himself about 3 - 5 months of weeknights & weekends....... he has almost finished painting the car with epoxy sealer.
Sound proofing insulation
The body painted inside & out
The wagon outside of Geelong Panel Beating Works.
Entire inside insulated & painted
Ready for the seats and carpet
The dash has been painted, floor insulated & sound proofed. The old wagon is ready for the new carpet & newly trimmed seats.
Doors have just been painted in the booth by Geelong Panel Beating Works
Looking tidy underneath
The black paint makes the wagon look tidy. You can see the new brake lines & the new leaf springs that have both been replaced. This work was done by McCallum Steering & Susp Geelong & Maltech Geelong
Freshly painted with new rubbers, tie rods etc.
New Brake Booster and fresh engine bay
An overhauled brake booster with a fresh new looking engine bay.
New radiator / cooling system
Was going to use the XE radiator but no way it will fit without major mods. Fitted a 3-core XP rad in place & clears nicely. Will have to use either a thermo fan at the front or a flat aftermarket fan, but that shouldn't pose a problem.
XE engine back in
Wazza pre-trial fitted the engine & auto. Was going to use the bw40 that came with the later motor, but when I trial fitted it to the car, the housing was longer than the orig bw35 and the speedo cable boss struck the underside rib in the floor. Also, the gbox mount was a real pain to fit/modify. So he decided to fit the bw35 & re-fit and it went in like a dream. Used the original mounts & everthing cleared nicely underneath & still plenty of clearance at back of engine. Column shift linkages fit perfectly as well Only other problem was the waterpump shaft too long on the 4.1 so had to grind a bit off the front.
Trimming seats door cards
The front and back seats as well as the door cards have all been reupholsted by C & N Motor Trimmers (Nth Sunshine Melbourne).
The front interior final product
The dash is complete with stock radio, knobs & dash. Wazza has lost the contact for who re-chromed the instrument cluster. He was really happy with his work & the end result & would like to use his services again for his XM Coupe project.
If you are reading this & you know that you did this work or know someone who did, could you please contact us at Overhaulcentral & we can add you to the web site displaying your details as well as put you in contact with Wazza.
Back seat & door cards
One of the best things about the xp wagon is how the back seat folds down to completely flat. There are metal supports designed to take extra weight. It is great to put a mattress, camping gear & surfboards into. You can sleep in it comfortably & fold it up when you have passengers. This beauty is ready for the beach!
Ready to put the back side glass in
Tail lights installed
Ready for front bumber & grill
The auto electrician still has to complete the wiring.
New Ford hub caps
These are not the original 1965 Ford Falcon Deluxe xp hub caps, athough they look great!
Wazza tells me that the hubcaps are 57 US Ford Fairlane dog dish caps.
Ready for the new hub caps
The whitewall tyres gives the old girl the classic style.
Completed Shot in Wazza's Garage
The only part that still needs to be put on is the sun viser.
Rear drivers side view.
Would you buy this used car, 40 something years old??
The wagon has been on the road for a bit over a year now and is going brilliantly. Has done a holiday trip from Geelong to Echuca where the old girl ran like a top and it’s had a summer hauling cricket gear etc around in high 30’s heat with not a hiccup.