Hey mate. I'm fairly familiar with old Falcons and can pretty much help
you with what you need to be aware of.
Like any car of it's age finding one without rust is a practical
impossibility, and like most cars of their age they have common areas
that are obvious. Places sills (as you've seen), floors and rear lower
quarters are all fairly common for the era. However early Falcons have
some particular areas to be aware of such as rear wheel arches (inner
and outer), boot floors, the folded lip around the boot opening on the
quarter panels (especially in the corners), front scuttle panels behind
the bumper, front suspension outrigger brackets and front cross-member.
There's also fairly common areas for different body types, such as utes
always rust out the rear floors and spare wheel area. Wagons lose
tailgates, rear floors and rear side window areas (and the rear side
window rubbers are hard to come by). Sedans often rust around the lower
rear windscreen corners and coupes quite often cop a fair amount of rust
in the lower sections of the front and rear roof pillars.
By far one of the most common areas to all of them, and one of the most
difficult to repair is the lower wiper scuttle panel. The cars have a
"flow through" ventilation system where air is drawn in through the
slots in the wiper panel and blown out through the vent boxes under the
dash on either side of the car. Water follows this path too and is
supposed to exit out through an opening in the side of the lower scuttle
and drain off, but after a few years of dirt, leaves and whatever else
managed to find it's way in there the drain paths become blocked and
water pools and rusts the tin away with the first sign of there being a
problem is when water leaks into the front floor on either side of the car.
This is the area in question here:
>
http://i31.photobucket.com/albums/c389/dasgib/000_0054_zpsf8hdvxhl.jpg
Trouble is, to get access to it the viper valance panel needs to be
removed, and in order to do that you need to remove the windscreen and
unpick about 250 spot welds to remove the panel:
>
http://i31.photobucket.com/albums/c389/dasgib/000_0051_zpsq3q1wlby.jpg
Which is hard fucking work!
They tend to get very thin in this area with water pooling every time
the car is exposed to rain, and often the easiest fix is to simply cut
the "corner" out and fabricate a new one:
>
http://i31.photobucket.com/albums/c389/dasgib/000_0123_zpsbqwpj1vr.jpg
You don't say what it is or if you're buying it for yourself, but I've
collected a heap of resources for these things over the years, and have
a few contacts for parts and other bits and pieces. If you need
anything, I'm happy to help although I'll say at the outset that the
very hardest thing for them to obtain is factory stainless trim that was
originally fitted to the outside of the car along the sides. "Deluxe"
stuff isn't too bad sometimes but "Futura" trim is next to impossible to
find in individual pieces let alone complete sets and when it *is*
around people generally ask stupid money for it.
HTH.
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Regards,
Noddy.