smooth firewall

[bfink]

i was going to get some work done on my 55 this weekend and one of the projects i need to tackle is filling the tons of holes in the firewall , i was thinking about just making an 18g or so plate and welding it on to the firewall . anybody do this ? pics ?

[OrrieG]

Do a search, we talk about this about every two weeks. Back up small holes with a strip of copper and weld them shut. I cut patchs out of 18 GA like you said and just spotted it in moving in a circular pattern. Keep cold water and a rag handy to reduce warpage. I had about 50 holes from 1/8" to 2" and it took me 8 hours to weld, 8 to grind and about 12 in body work.

[72Mountaineer]

Check out Custom Classic Trucks....tech....smoothing a firewall. Can't do a link, sorry.

[hsdropout]

I cut a couple pieces of sheet aluminum to fit the upper areas and riveted them on...... planned on putting an old school "engine turn" pattern on them.......but ended up priming them with the rest of the cab (impatient). Don't have a drill press to do the engine turning, I can always take them off and use them as patterns for custom pieces. The flat covers provide for a little more insulation space on upper firewall too.
It's not too cheesy for a DD.
All the holes below were welded up.

[jimig1]

I cut out and replaced some of it

[bfink]

thanks ! i was planning on welding up every hole like in Orrieg's pics but now im kinda leaning towards smoothing the whole thing out .

[Dan in Pasadena]

Originally Posted by bfink

thanks ! i was planning on welding up every hole like in Orrieg's pics but now im kinda leaning towards smoothing the whole thing out .

Me too because I kinda like the factory stamped ridges, BUT...I've also considered using something LIKE this:

http://www.nolimitparts.com/prodinfo.asp?number=CFWC

Seems like it would be SO much less work and for a non-"show" but nice driver I think it might be okay. Anyone have any experience with this or possibly a metal one (if someone makes such a thing)?

[_Ogre]

I'm a fan of the factory ribs.
This cost me nothing except some welding wire.



$205 for a plastic firewall is a shame
Posted via Mobile Device

[bfink]

i've seen those fiberglass covers too , but i dont know if anyone else with a camaro subframe has firewall clearence issues but i do ! i mean its not that bad but it close enough that i need all the room i can get . i made some thin cardboard templates today gonna see if i can get somebody to cut some out for me. Either way ( filling holes or welding covers on) im not very confident in my welding skills . I only have a little 110 wire feed welder and flux core wire but i guess practice makes perfect so we'll see.....

[bfink]

Ogre.....it took a few minutes of looking at your firewall thinking "something looks different" but then i got it , you shaved the lip right ? how hard was that ?

[Russell Ashley]

"Seems like it would be SO much less work and for a non-"show" but nice driver"

For a driver, less work for me was welding up the holes that PO's had chiseled into the firewall and painting it and calling it good. I like the ridges and use the seam to support my wiring, so wouldn't want to remove it. My truck is definitely "non-show" BTW.

[bfink]

Originally Posted by 72Mountaineer

Check out Custom Classic Trucks....tech....smoothing a firewall. Can't do a link, sorry.

thanks ! i just picked that issue last night , thats exactly what i was talking about

[Dan in Pasadena]

Originally Posted by Russell Ashley

I like the ridges and use the seam to support my wiring...

Not sure I understand what you mean by this? Can you explain?

BTW, I'm not saying the plastic firewall cover is the be all/end all, just added it to this thread for future lookers. I intend to weld my holes shut, save the $200+ and feel good knowing "I did that".

[_Ogre]

Originally Posted by bfink

I only have a little 110 wire feed welder and flux core wire but i guess practice makes perfect so we'll see.....

my firewall was welded with a 110v flux core lincoln weldpak 100
yes practice makes perfect and the firewall is a good thing to practice on...
to cut out the seam? remove a couple of 6'' sections and start welding.
easy peasy...

[Russell Ashley]

Dan, I'm more into function than looks with this truck. Not many people will ever see under the hood of my truck any way. I used self drilling screws and black cable mounting ties to hold that part of the harness up along the ridge. The green looped wire is for an under hood light that I will add eventually.

[bfink]

[QUOTE=_Ogre;5313092]my firewall was welded with a 110v flux core lincoln weldpak 100
yes practice makes perfect and the firewall is a good thing to practice on...
to cut out the seam? remove a couple of 6'' sections and start welding.
easy peasy...

[/QUOTE
yours looks great! i think im going to leave the seam as a paint break....gonna be black wrinkle paint below , body color above

[Dan in Pasadena]

Originally Posted by Russell Ashley

Dan, I'm more into function than looks with this truck. Not many people will ever see under the hood of my truck any way. I used self drilling screws and black cable mounting ties to hold that part of the harness up along the ridge. The green looped wire is for an under hood light that I will add eventually.

Looks clean, neat and organized....I wish mine did!

[Rude Dude]

I used elevator bolts to fill a lot of the big holes, I did this to give me studs on inside to run wire retainers and future A/C attachment points, what ever I don't use I can hack the stud screws off.

[_Ogre]

my ramjet 350 has a 3/4'' harness just for the motor, i ran it thru the distributor hump
all my front wiring was run thru the grey flex conduit next to my ac lines

[1956chevtruck]

Here's what I did. Various stages along the way.

[dsl30263]

Wow! Clean.

[48 GMC BURB]

Sweet work. With the LT 1 do you need the recess or could you go totally smooth ? I am putting a 96 corvette drive train & suspension in a 51 AD pick up,
KC

Originally Posted by 1956chevtruck

Here's what I did. Various stages along the way.

[Rods57]

Weld, prime, sand, prime, sand, prime, sand, prime....

[1956chevtruck]

Originally Posted by 48 GMC BURB

Sweet work. With the LT 1 do you need the recess or could you go totally smooth ? I am putting a 96 corvette drive train & suspension in a 51 AD pick up,
KC

Could have probably gotten rid of the recess all together however, I like the old school like and feel!

[Dan in Pasadena]

1956chevtruck - What's your color? Very, very nice.