wpdb11af59.png
wpfce22810.png
wpaba357ab.png

© 1998-2008 Joe Weaver

 

wp1d7e90c7.png













wp376711fc_0f.jpg
wpb961d075.png
wpde4fb5c8.png

My Sprint came from the factory with front bucket seats and a center console between them. While the console was still in quite good shape, it definitely was looking a bit tired. The chrome pieces were dull and pitted, the lid was cracked and scratched up, and the aluminum tray was really looking bad. It needed some attention if it was to look as good as I intended the rest of the car to look. Rebuilding the console is really an easy task. Disassembly is simple. The main part of the project that needs some planning and preparation is that the chrome pieces needed to be rechromed and the stainless side rails needed to be polished. The screws were very dull and a bit rusty and also needed polishing. As mentioned above, the aluminum tray insert was quite scratched and dented so it needed to be replaced, and the lid needed replacement as well. Once I had all the pieces either replaced or refurbished, assembly of the console only took about 45 minutes. While new (reproduction) console bodies are available, I intentionally decided to keep my original console body even though it was a bit scratched up. My original goal in this restoration was to return this car to the way it was when new; however, I was replacing so many parts of the car with new ones that I was beginning to feel it was turning into a different car than my old high school & college friend. As a result, I decided to keep several items that I could have replaced just so I could feel like I had the same car. The console body was one of them. After the car is done and I am driving it, I know I'll be able to reach down and touch it and know it is the exact same console I had so many years ago.

wp494d4b02.jpg wpf6f771c5.jpg

The left photo shows the metal trim pieces. The blue arrows show the chromed pieces, the green arrows show the stainless steel side rails, and the red arrow shows the aluminum tray insert.ýÿ The right photo shows the console body (blue arrow), the lid retaining rod is shown by the red arrow. The lid is shown upside down (green arrow). The yellow arrow points to the latching stud, the brown arrow points to the bracket for the lid retaining rod, and the pink arrow points to the lid hinge bracket.

wp980f1a8c.jpg

This view is with the lid upright. The blue arrow shows the stainless steel accent trim for the lid. The red arrow shows the back side of the mounting bracket, and more directly points to the backing plate. Instead of screws and nuts, Ford used screws and a backing plate with three threaded holes for the screws.

wp5ebf4f33.jpg

This photo shows the old (bottom) and new (top) lids, with the accent trim piece sitting on top. I glued the trim piece to the new lid with contact cement after cleaning both the trim and the lid with rubbing alcohol (I didn't want to risk damaging the lid with paint or lacquer thinner). In actuality, the new lid didn't look much better than the old one. I will point this out later.

wpd048c1e4.jpg wp6936e931.jpg

The aluminum tray insert is a little tricky to install. Firstly though, the tray insert that was in my Sprint had a black stripe around the edges as in the photos above; however, when this insert arrived there was no black stripe on it so I needed to carefully mask it and paint the stripe to match the original one. In the left photo above, red arrows point to slots in the console body for the side tabs on the tray insert to go through. Blue arrows in the left photo point to the side tabs on the tray insert as they were shipped, but these need to be bent down to fit in the slots. The blue arrows in the right photo show them bent down.

wp7690244b.jpg wpbae597f6.jpg

The left photo just shows a trial fit of the tray insert tabs into the slots in the console body. But the tray insert is really installed in the chrome trim piece before installation in the body. The right photo shows it resting in place in the chrome trim (although it is installed from the bottom).

wp9daefd3c.jpg

This shows the tray insert installed in the bottom side of the tray chrome trim. The blue arrows show five attach points, or stays, for the tray insert. This is the most difficult part of the console rebuild. To install the tray, position the tray so that it is just short of sliding under the front stay but still free of it. Then slide one side of the tray under the stops on that side (red arrows). Now comes the difficult part. You need to slightly bend the tray in the middle so that you can get the other side of the tray under the stops on that side of the chrome trim (green arrows). You need to be careful so as not to damage the tray insert by bending it too much as well as from scratching the brushed side of the tray. After the tray is under both stays on both sides, slide it slightly forward to catch under the front stay (yellow arrow).

wp0857de99.jpg wpc540782f.jpg

These photos are close-ups of the side stays (green arrows) and front stay (yellow arrow). One of the tray insert tabs is visible in the right photo (blue arrow). Although not readily visible in this photo, the red arrow above points to a small retainer tab or protrusion that prevents the tray insert from sliding backwards so it is locked in place. As an alternative to bending the tray insert so as to be able to get the tray under both side stays, these two tabs (red arrow, one on each side) could be bent down, the tray simply slid into place and then these retainer tabs bent back flat to keep it in place. I chose not to do this since there is little overlap of the aluminum tray material and I was concerned that too much bending would show up on the dress side of the aluminum piece.

wp6eac8e24.jpg wpd80c58b7.jpg

The left photo shows the completed tray assembly set in place in the console body. The right photo shows the console body upside down. The red arrows in the right photo show the threaded studs from the chrome tray trim protruding through the body to which nuts are attached. The blue arrows in the right photo show the tray insert tabs protruding through the slots in the console body. These are bent to the sides to hold the front of the tray in place as shown below. Note the rag under the chrome tray trim to prevent scratching.

wp200bd47b.jpg wpb72b5f8e.jpg

These photos are close-ups of the tabs bent over

wp0b7fc700.jpg

This photo shows the latching clip for the lid stud. It is mounted from beneath but the screws are inserted from the top. This clip is adjustable front to rear to accommodate final lid position.

wpdb4900a5.jpg wp8e4cd2cd.jpg

These photos show the lid retaining rod and its associated spring. The left photo shows the spring as it was when I disassembled the console. It had slipped out of the loop in the end of the rod and was totally useless. The photo on the right shows the spring properly installed.

wp16af0a28.jpg

This is a photo of one of the screws that holds the rear chrome trim and stainless steel side rails in place. Even though the screws are stainless steel themselves, several had rusted slightly (as seen above), and all were dull and lacked luster. These were easy to polish up as seen below.

wp8acf963d.jpg wp546e0edd.jpg

I set the screw lightly in the chuck of a cordless drill (tight enough to hold it while polishing but loose enough to prevent thread damage) and then, while running the drill at slow to medium speed, lightly pushed 0000 steel wool onto the head of the screws. It took some time on the worst looking screws, but as you can see above they polished up quite well. I had to use my fingernail to push the steel wool into the low parts of the screw head.

wp03590a9a.jpg

There are six short screws for the side rails, and three longer screws for the rear chrome trim piece.

wp91654ff6.jpg

This shows the tray assembly in place, and the rear chrome trim piece installed (red arrow). These two pieces are installed before the side rails since the rails slightly overlap the chrome pieces. The right stainless rail is also installed (note the lid retention rod). The left rail is not installed just for clarity of installation order.

wp744c627d.jpg

This is the door hinge bracket. As noted above, there are three holes for screws in the bracket (red arrow). The screws go through the hinge bracket, through the plastic console body and thread into the backing plate (green arrow). The three nuts (blue arrows) thread onto studs that are integral in the lid. The holes for all six of these mounting points are large to accommodate forward/rearward & left/right adjustment to get the lid to fit properly.

wpe2c59aa6.jpg

This shows the console complete and ready for installation in the car.

wpdadbc32c.jpg wpe01825f3.jpg

As mentioned above, I was extremely disappointed at the apparent lack of quality of the rear portion of the new (reproduction) lid. While the original stock lid was similar, this looks even worse on the rear edge. As of the writing of this edition I had not taken the time to research and see if perhaps there was some sort of trim piece that was originally installed on the rear of the lid. It looks as if the rear edge was molded to fit some sort of piece of trim that I am missing (if any of you are aware of such a piece please email me).

wpf3e53391.jpg

Another area I am disappointed in is the quality of the stainless center strip for the door. While it is not horrible, it certainly is not of high quality as this photo shows.

 

Rebuilding

the

Console

This is the end of the

Rebuilding the Console Edition

wpbd47a013.gif
wpbd47a013.gif
wpf19c5627.jpg

Feel free to save this page to your computer for your personal use and future reference--no other use is authorized without prior written permission from me. All illustrations from the 1964 or 1965 Falcon Shop Manuals used pursuant to permission granted by Ford Motor Company. Disclaimer: This site is not intended to instruct or teach anyone in proper or safe methods of working on or maintaining any type of vehicle or use of any tool and the author takes no responsibility for the use of the information contained herein.

If you have comments or suggestions, email me at joe@joesfalcon.com

Discussion & Procedure

Overview

wpe4de1338.png
wpe4de1338.png