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DIY Driveshaft Tunnel for the LS AR5 swapped 1963 Ford Falcon

Posted by Fish ON!!!!!!! on September 11, 2022

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Project 315....A DIY frame notching/mini tub

So I have finally decided to go forward with Project 315. They plan is to stuff a 315/35/17 under the Falcon. I found a good right up on TFFN with lots of pictures. I will be copying his work except for I will be using prefabbed wheel tubs from Summit Racing. After the frame notching and leaf spring relocation I should have 14 inches of tub to fit the 12.5 inch tires into. A lot of people will not tackle a project like this because you need expensive tools, but you really don't. I don't have an air compressor or anything to fancy. I use a Harbor Freight cut off saw that cost $29 and a Harbor Freight nibble that cost $45. My welder is a Hobart that I got off of Craigslist. The welder matters. The big three are Lincoln, Miller, and Hobart. All the other cheap ones make it hard to weld thin metals because they don't control the heat as well. You can do this with a new cheap welder, but I recommend buying a good used one. Harbor Freight Cut-off saw. Works great so far.

A list of headers that fit a 1963 Ford Falcon

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Notching the shock towers on a 1963 Ford Falcon

With the motor mounts complete it was time to do something about the shock towers. I did a lot of looking online and couldn't find anything that was Falcon specific. I found shock tower notching for Mustangs, Mavericks, and Fairlanes, but no Falcons. I found a few really good write ups on doing Mustang shock towers and decided I would follow one of their write ups and just add a little tweaking for the Ford Falcon. On Mustangs most people take 2" off of the bottom and a 1/2" off of the top when notching the shock towers. I did some measuring and marked of 3" on the bottom 1/2" on the top, but got nervous after reading that 2" was the maximum. Marking the shock tower of a 1963 Ford Falcon for notching I decided to make a mark at 2" and then come up with a way to check spring clearance before doing any cutting. What I came up with was drilling small holes where the corners would meet and running some steel wire through them so I could measure on the

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