Following the sale of Gordon's and Grant's replica Interceptors, these two were in possession of years of accumulated Mad Max and XB Falcon knowledge. They also had access to all of the correct moulds, and the established connections and support structure for the further manufacture of Mad Max replicas. So as Grant and Gordon both enjoyed the Mad Max Interceptor history and myth they eventually said yes to the building of another replica.

     Now they are at the point that they are happy with the production standard of the replicas. Like everything in life, the more you do of something the better you get at it. It can honestly be said that it was not until the third replica that they became truly satisfied. As you can see form Gordon's original replica, the building has been refined since that first Interceptor replica was built. The replicas are now the living image of the Mad Max 1 Movie car.

     Preparation and building of a replica Interceptor:

     When an order for a replica is placed and deposit installed, Gordon and Grant commence looking for the base car to start the replica building process. So far they have always looked at complete cars, but with the rarity of coupes now escalating, it looks more like the future will include picking up shells and building from there. This makes sense as every coupe needs to be stripped back to the shell in order for the rust areas to be identified and repaired. Also in their long life, the coupes have usually always been modified by perhaps many, many owners, each with a different preference. So many things could have been changed: interiors, head linings, cracked dash pads, extra gauges, lost gauges, changed color inside, windshield scratches, side window scratches, worn body shell rubber, entire drive trains have often been swapped, modified and changed around, plus a multitude of other issues that are either worn out parts, or are not consistent with the original Ford product at all.

     Assuming they find a complete base car like the one pictured, the next job is to strip the car to a shell. It has been found that this is the only way to establish the exact condition of the car. The red car pictured is a good example of what can happen in a coupe's life. To look at it, it looks like it is an XA GT Falcon. Looks can be deceiving because in fact it is really a later model XB Falcon changed entirely to look like an XA. The previous owners changed everything right down to a worn XA GT interior. No sign of the XB model remained at all, just a compliance plate indicating XB and 1975 production.

     Once the vehicle is stripped, and only the shell is left, the hanging panels are then removed and the rust repair work begins. Grant finds and cuts out the rust and then welds in new steel to replace the lost metal. The early Falcons are classic "muscle" cars in design, being V8 powered and genuine beasts of cars. Though they are nice to look at, the inherent 30 year old design had many areas that held water. We are still hard pressed to find a Falcon that has not rusted under the front guard. This under-guard rust area is a pain as it is out of sight until the car is stripped down with all off the hanging panels removed. A spot welded support brace section then needs to be drilled free of the car and only then, deep in the cars body shell, can the repair work begin.

     Once the rust is gone the repaired areas are treated, the entire front and rear suspension is removed and then the re-assembly begins.

     During this time we have also commissioned our fiberglass mould maker/supplier to provide a new set of Mad Max fiberglass parts. At this time Gordon begins the long job of fitting and blending the roof spoiler, trunk spoiler, and flares into the body. After Gordon has added the light buckets and Grant has manufactured the replicated mounting bracket, the Monza nose is then fitted and blended into the body also.

     Grant then assembles the new front suspension (i.e. tie rod ends, pittman arm, ball joints, nolethane bushes, new springs, and sway bar). He fits all of this to the base car. Meanwhile, Gordon will be cleaning up the engine bay to get it ready for fresh black paint. The steering box is then changed to a GT model, running the specification of four turns lock to lock. Then a new brake master cylinder is added. The disk brake equipped 9" LSD rear differential goes into position at this point to keep the shell as a "roller" for the painters. The traction bars are then fitted and new suspension bushes go in. Nolathane is used for all bushes.

     In all cases the interior will be replaced with an entire new interior done to Falcon XB GT specifications. This is what Max had, so this is what you the buyer will have. This means that the headliner will be replaced with the bone color that Max had and everything down to the center console, seat belts and rear parcel shelf will be brought back to standard GT specification. Like any restoration or rebuild, this is a slow section of work. In the red base car pictured the wiring had been so modified over the years that Grant removed the entire front loom, and "simply" started again from scratch. In most cases Grant returns the wiring to factory stock specification. This is the safest and most correct option. 

      Once the wiring is repaired, the engine and gearbox can be returned. In the case of the red coupe, the donor engine was a high performance build from a local engine shop, so our work was simply removing the sump and checking its general condition. As the engine was a proven performer and already freshly built there was no reason to mess with it. We then add a reconditioned gearbox, and rear diff / axle assembly. In all cases we add a disc brake rear end along with the traction bars as used by the GT falcon. With just this hardware installed, the base car goes out for painting. At this stage it is still just a shell, no glass, no interior, and the ugly old transport wheels fitted. At the painters the gloss paint is applied and buffed. Then Grant and Gordon attend to the taping-up of the car for the satin black paint. Their first taping on the third replica took 6 hours,  but they are now down to about 4 hours for the pre-satin mask-up.

    Once the replica is returned, the re-assembly begins. First the replica goes to the auto upholster and the seats are re-trimmed and re-padded back to new condition. The headlining is replaced with a new lining in the correct color. The roof console is made up by Grant while the replica is being painted so once the head lining is fitted Grant then fits the roof console. Rear interior courtesy lights are fitted as per GT Falcons. A new rear parcel shelf is fitted, and the seat belts are re-manufactured so as to be new. New carpet is fitted, the GT center console goes in, the genuine Police siren is fitted, next the red "Supercharger " button is wired up and located on the gear shift. 

     If required, a GT dash is fitted. A new dash crash pad goes in and the blue light mount is made and positioned. All new side glass (all 4 windows) and a new windshield glass is fitted. At this point the rear window is also refitted after being removed for the Interceptors repainting. The custom made wheels return from the powder coaters and the big BFG Radial T/A's are fitted, then the wheels and tires go on the replica, along with new chrome wheel nuts and domes (center caps). The movie correct non-functional supercharger is then fitted and wired up. Reproduction custom made Scott Hats and Weiand covers are used since originals are extremely difficult to obtain. The entire drive system for the supercharger is custom made by engineers. 

     With the blower and wheels in position, the Interceptor now assumes the look and stance of the movie car. The rare ultra short blower drive belt is ordered and fitted. Gordon custom  makes each light cover and the cover's golding is applied by contractors. At this time the movie correct magnetic MFP decals are also ordered and fitted. From start to finish the strip down, repairs, and build up will take around 16-20 weeks, including the 2-4 weeks at the painters. Gordon and Grant build the replicas after work at there "normal" day jobs. They work as a team for approximately 2-3 hours a night on average, four nights a week and daylight till dark on Saturday. As a rule they don't work on Sundays at all. No work Sundays might be the rule, but like all car work it isn't necessarily so.

     Would you like to see a video about building an Interceptor, along with some footage of high speed chases in one, and a few cool burnout scenes? Email Grant or Gordon directly to purchase. Video information HERE.

     If you are serious, and would like to inquire about us building you your own replica, then contact either Gordon or Grant directly. We can also supply you with email contact addresses from previous customers, in order for you to obtain personal references about our work from them.

Thanks and have a great day!