Need some help, ideas, or suggestions - The 1947 - Present Chevrolet & GMC Truck Message Board Network

Trucknut57 · 08-09-2011, 02:05 PM

Just cleaned off the firewall and found a BUNCH of extra holes.

I have no idea what to do with all the holes. I know I have to weld a few of them up cause they are spliting the metal.

I need some direction. Unfortunetly buying a new firewall isn't an option at this time. I have a few ideas but just not sure of which route to go.

OrrieG · 08-09-2011, 03:00 PM

look at this. I welded up 45 or so in mine from pin hole to 1.25" dia. All the little holes are for stuff screwed on from both sides of the cab side and for holding the inside insulation in place. I welded studs on the inside for stuff that needed to stay.

Trucknut57 · 08-09-2011, 03:23 PM

Thanks OrrieG, studs on the inside is a good idea. I'll use that for a bunch of stuff. That can be used to fill a couple of the holes.

I just counted around 75 holes to fill. That sucks!

dicer · 08-09-2011, 08:50 PM

Theres a few there that the factory didn't put there. Wow

BlueJeep · 08-09-2011, 10:17 PM

Start cutting little sheetmetal plugs and begin welding. I made a sheetmetal plug for each of my holes and welded them in, even the 1/4" diameter ones.

FFredo · 08-09-2011, 11:13 PM

If I had that many holes to fill in I'd do it in large patches where possible. Cut out a section and weld in a section.

solidaxel · 08-09-2011, 11:13 PM

Blue Jeep has the idea, fill one at a time !!

**Dan in Pasadena** · 08-10-2011, 01:37 AM

Another option if you're not a welder:

http://www.nolimit.net/prodinfo.asp?number=CFWC

Maybe someone makes a metal one or you could make a metal one yourself with a sheet of 18 ga. and a cheap electric shear:

http://www.harborfreight.com/18-gaug...ear-92148.html

OrrieG · 08-10-2011, 12:40 PM

I got lucky, my wife was out of town for 2 weeks when I did mine so I got long hours in without interuption. As i recall I had one long day in cutting and welding in the patch pieces; one long day of grinding and touch up welding and a week of evenings removing the rest of the paint, smoothing and sanding with rage and priming. I wanted to keep the original recesses but no holes.

**Dan in Pasadena** · 08-10-2011, 01:34 PM

Quote:

Originally Posted by OrrieG

... sanding with rage...

That's how I feel EVERY time I sand.

(What's "rage" anyway)

1956chevtruck · 08-10-2011, 02:10 PM

Cut fillers, weld, blending disc, filler, sand, high build primer, paint, and voila!

Byron

hotrodrookie · 08-10-2011, 02:17 PM

http://www.webrodder.com/article.php...1&SID=60&CID=7

There are a ton of great articles on this website, I wish I knew about them before I ventured into my truck blindly.

For the really small holes I would just use a thick copper backup fill the holes with mig wire.

Russell Ashley · 08-10-2011, 03:15 PM

Trucknut57, If you were closer I'd think that the same person might have owned both our trucks at some point in time, based on the skills used in mounting a heater.
Sometimes I get the idea that that left hole is laughing at me. If it isn't the guy who sold me this truck probably is, LOL.

**Dan in Pasadena** · 08-10-2011, 03:37 PM

Quote:

Originally Posted by 1956chevtruck

Cut fillers, weld, blending disc, filler, sand, high build primer, paint, and voila!

Byron

Byron,
I REALLY like the Fuel Injection badge on your cowl. A very nice little touch. Thanks, Dan

Russell,
That hole really DOES look like the metal god laughing at you!

EDIT: P.S. to Byron, What are the other plugs or whatever they are on your firewall? Backsides of mounts for....AC? Could you have welded on studs? NOT criticizing cause your truck ROCKS, just asking for future reference.

No one picked up on my links of firewall covers. Are they a faux pas I am unaware of? Seems like a fast easy way of improving your firewall...though admittedly not as nice as original filled/painted with factory recesses.

Trucknut57 · 08-10-2011, 03:57 PM

Russell,

I know exactly who did the butcher job on the firewall, my Dad! He didn't care about the looks, he just want the items mounted. Now I get to straighten out his hack job, lucky me.

Byron,

Where did you put the battery?

Russell Ashley · 08-10-2011, 04:40 PM

I put the battery back in the original location. It kind of "uglies" up the firewall but I'm making a driver and didn't want to make more work for myself by moving it. I'm planning on installing an Old Air setup so I didn't weld up the factory heater holes, I just tacked in a plate behind each one that I can remove if I need to.

OrrieG · 08-10-2011, 08:01 PM

Evercoat Rage plastic filler (like bondo only better). Frog green instead of pink.

OrrieG · 08-10-2011, 08:02 PM

Quote:

Originally Posted by Russell Ashley

I put the battery back in the original location. It kind of "uglies" up the firewall but I'm making a driver and didn't want to make more work for myself by moving it.

Me too, I figured the time the battery gave me problems would be when it was buried under a bunch of camping stuff in the bed or if under the frame sunk in a mud hole.

**Denee007** · 08-10-2011, 08:30 PM

omg, I just realized i'm going to have my engine out in a few weeks and I'm going to have this same problem : ( Glad this thread was started! More learning and doing!
dne'

1956chevtruck · 08-11-2011, 12:51 AM

Hey Dan thanks. The 6 nuts are for my custom heater and I wish that I did weld nuts on the inside of the firewall. I'm just enjoying it for now, but yes I am going to fix those and make the firewall totally smooth.

Trucknut57 the battery is under the step and the passenger side. It makes for and run of about 16" to the starter, however, a little difficult to get at. But man does it clean up the engine compartment.

Byron

08-09-2011, 02:05 PM	#1
Trucknut57 Registered User Join Date: Aug 2010 Location: Jennings, OK Posts: 322	Need some help, ideas, or suggestions Just cleaned off the firewall and found a BUNCH of extra holes. I have no idea what to do with all the holes. I know I have to weld a few of them up cause they are spliting the metal. I need some direction. Unfortunetly buying a new firewall isn't an option at this time. I have a few ideas but just not sure of which route to go. __________________ Somehow, the idiots survive despite their best efforts to kill themselves. - dcozzi

08-09-2011, 03:00 PM	#2
OrrieG Registered User Join Date: Jun 2006 Location: Idaho Posts: 8,800	Re: Need some help, ideas, or suggestions look at this. I welded up 45 or so in mine from pin hole to 1.25" dia. All the little holes are for stuff screwed on from both sides of the cab side and for holding the inside insulation in place. I welded studs on the inside for stuff that needed to stay. Attached Images __________________ 1959 Chevy Short Fleetside w/ 74 4WD drive train (current project) OrrieG Build Thread 1964 Chevelle Malibu w/ 355-350TH (daily driver) Helpful AD and TF Manual Site Old Car Manual Project

08-09-2011, 03:23 PM	#3
Trucknut57 Registered User Join Date: Aug 2010 Location: Jennings, OK Posts: 322	Re: Need some help, ideas, or suggestions Thanks OrrieG, studs on the inside is a good idea. I'll use that for a bunch of stuff. That can be used to fill a couple of the holes. I just counted around 75 holes to fill. That sucks! __________________ Somehow, the idiots survive despite their best efforts to kill themselves. - dcozzi

08-09-2011, 08:50 PM	#4
dicer Registered User Join Date: Dec 2010 Location: seattle, wa Posts: 529	Re: Need some help, ideas, or suggestions Theres a few there that the factory didn't put there. Wow

08-09-2011, 10:17 PM	#5
BlueJeep Registered User Join Date: Mar 2008 Location: Waukee, Iowa Posts: 1,608	Re: Need some help, ideas, or suggestions Start cutting little sheetmetal plugs and begin welding. I made a sheetmetal plug for each of my holes and welded them in, even the 1/4" diameter ones. __________________ build threads: 86 Suburban 88 Jeep 6.0 swap 49 Chevy truck 54 Chevy wagon 86 Suburban lowered 4/6 54 Chevy wagon 49 Chevy/s10 mix 88 Jeep Wrangler rockcrawler

08-09-2011, 11:13 PM	#6
FFredo Registered User Join Date: Apr 2011 Location: San Diego CA Posts: 241	Re: Need some help, ideas, or suggestions If I had that many holes to fill in I'd do it in large patches where possible. Cut out a section and weld in a section.

08-09-2011, 11:13 PM	#7
solidaxel Registered User Join Date: Dec 2002 Location: Cactus Patch So. Az Posts: 4,749	Re: Need some help, ideas, or suggestions Blue Jeep has the idea, fill one at a time !! Attached Images __________________ 53 TuTone Extended Cab 350 4-Spd 3:08 (SOLD) 53 Chevy Moldy pearl green ZZ-4 4L60E 9" 3:25 55 GMC 1st Black Mll (ZZ4) ZZ6 TKO 600 5 sp 3:73 62 Solidaxle Corvette Roman Red (327 340hp 4spd 3:36) C4 & C5 suspension tube chassis LS 3 4L70E 65 Corvette Coupe 327 350hp 4spd 4:11 78 Black Silverado SWB (350/350) 5.3 & 4L60E 3:42 2000 S-Type 3.0 (wife cruiser) 2003 GMC SCSB 5.3 4L60E 3:42

08-10-2011, 01:37 AM	#8
Dan in Pasadena Senior Member Join Date: Nov 2008 Location: Glendora, CA Posts: 6,345	Re: Need some help, ideas, or suggestions Another option if you're not a welder: http://www.nolimit.net/prodinfo.asp?number=CFWC Maybe someone makes a metal one or you could make a metal one yourself with a sheet of 18 ga. and a cheap electric shear: http://www.harborfreight.com/18-gaug...ear-92148.html

08-10-2011, 12:40 PM	#9
OrrieG Registered User Join Date: Jun 2006 Location: Idaho Posts: 8,800	Re: Need some help, ideas, or suggestions I got lucky, my wife was out of town for 2 weeks when I did mine so I got long hours in without interuption. As i recall I had one long day in cutting and welding in the patch pieces; one long day of grinding and touch up welding and a week of evenings removing the rest of the paint, smoothing and sanding with rage and priming. I wanted to keep the original recesses but no holes. Attached Images __________________ 1959 Chevy Short Fleetside w/ 74 4WD drive train (current project) OrrieG Build Thread 1964 Chevelle Malibu w/ 355-350TH (daily driver) Helpful AD and TF Manual Site Old Car Manual Project

08-10-2011, 02:10 PM	#11
1956chevtruck Registered User Join Date: Jun 2004 Location: Qualicum Beach British Columbia Canada Posts: 132	Re: Need some help, ideas, or suggestions Cut fillers, weld, blending disc, filler, sand, high build primer, paint, and voila! Byron Attached Images

08-10-2011, 02:17 PM	#12
hotrodrookie Registered User Join Date: Sep 2008 Location: Sacramento Posts: 425	Re: Need some help, ideas, or suggestions http://www.webrodder.com/article.php...1&SID=60&CID=7 There are a ton of great articles on this website, I wish I knew about them before I ventured into my truck blindly. For the really small holes I would just use a thick copper backup fill the holes with mig wire.

08-10-2011, 03:15 PM	#13
Russell Ashley Registered User Join Date: May 2010 Location: Lawrenceville, Ga Posts: 2,648	Re: Need some help, ideas, or suggestions Trucknut57, If you were closer I'd think that the same person might have owned both our trucks at some point in time, based on the skills used in mounting a heater. Sometimes I get the idea that that left hole is laughing at me. If it isn't the guy who sold me this truck probably is, LOL. Attached Images

08-10-2011, 03:57 PM	#15
Trucknut57 Registered User Join Date: Aug 2010 Location: Jennings, OK Posts: 322	Re: Need some help, ideas, or suggestions Russell, I know exactly who did the butcher job on the firewall, my Dad! He didn't care about the looks, he just want the items mounted. Now I get to straighten out his hack job, lucky me. Byron, Where did you put the battery? __________________ Somehow, the idiots survive despite their best efforts to kill themselves. - dcozzi

08-10-2011, 04:40 PM	#16
Russell Ashley Registered User Join Date: May 2010 Location: Lawrenceville, Ga Posts: 2,648	Re: Need some help, ideas, or suggestions I put the battery back in the original location. It kind of "uglies" up the firewall but I'm making a driver and didn't want to make more work for myself by moving it. I'm planning on installing an Old Air setup so I didn't weld up the factory heater holes, I just tacked in a plate behind each one that I can remove if I need to. Attached Images

08-10-2011, 08:01 PM	#17
OrrieG Registered User Join Date: Jun 2006 Location: Idaho Posts: 8,800	Re: Need some help, ideas, or suggestions Evercoat Rage plastic filler (like bondo only better). Frog green instead of pink. Attached Images __________________ 1959 Chevy Short Fleetside w/ 74 4WD drive train (current project) OrrieG Build Thread 1964 Chevelle Malibu w/ 355-350TH (daily driver) Helpful AD and TF Manual Site Old Car Manual Project



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08-10-2011, 08:30 PM	#19
Denee007 Senior Member Join Date: May 2011 Location: Cypress, Tx. Posts: 1,504	Re: Need some help, ideas, or suggestions omg, I just realized i'm going to have my engine out in a few weeks and I'm going to have this same problem : ( Glad this thread was started! More learning and doing! dne'

08-11-2011, 12:51 AM	#20
1956chevtruck Registered User Join Date: Jun 2004 Location: Qualicum Beach British Columbia Canada Posts: 132	Re: Need some help, ideas, or suggestions Hey Dan thanks. The 6 nuts are for my custom heater and I wish that I did weld nuts on the inside of the firewall. I'm just enjoying it for now, but yes I am going to fix those and make the firewall totally smooth. Trucknut57 the battery is under the step and the passenger side. It makes for and run of about 16" to the starter, however, a little difficult to get at. But man does it clean up the engine compartment. Byron Attached Images

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