1970 Cutlass Firewall Shave.

[DreKoushRanada]

I figured That a shaved firewall is an awesome addition but I have a few questions. Instead of paying $250.00 for a pre-made piece I decided to make my own out of some 18g sheet metal I had laying around from rust repair work. I made a template using poster board and transferred it to the metal. It is not perfect at all but I feel it should do the job. I am cutting out the the window wiper motor hole and welding it behind the driverside fender. I attached the metal for fitment purposes with 1/2 sheet metal screws.

https://static1.pt-content.com/images/pt/2016/09/20160903_170408_zps7qhpxz7s-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/20160903_170408_zps7qhpxz7s.jpg.html)

https://static1.pt-content.com/images/pt/2016/09/20160904_205609_zpsnqjgjznh-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/20160904_205609_zpsnqjgjznh.jpg.html)

https://static1.pt-content.com/images/pt/2016/09/IMG_20160904_212436_zpsvrio5xpc-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/IMG_20160904_212436_zpsvrio5xpc.jpg.html)

The template came out a bit small but that will be corrected with a duraglass/kitty hair type bondo.
My biggest obstacle is figuring out how to weld the part in front of the wiper motor. It is difficult because it is recessed.
Can I cut/grind down the cowl lip that overhangs the firewall?

[raustinss]

You can trim it ... I wouldn't cut it off completely due to the fact it's multiple layers that come together there .... If you do cut it off you would probably want to have some angle welded inside under the dash in that location. Remember that firewall / cowl area is a "stressed". Area and quite important

[DreKoushRanada]

You can trim it ... I wouldn't cut it off completely due to the fact it's multiple layers that come together there .... If you do cut it off you would probably want to have some angle welded inside under the dash in that location. Remember that firewall / cowl area is a "stressed". Area and quite important

Good deal. I will just trim an inch or so off.

[raustinss]

There was a chevelle build on here ...kinda a stale build now but do a search of black widow chevelle.. It's a 70 and the owner Tim did trim/shave his and then ran a piece of round bar welded to it . Without going to the garage to look I'd say there is 3 layers (firewall, bottom of cool and top side of cool) minimum possibly more at the sides . So no matter if you trim it or not you will run into the spot welds along it , trim off an area and weld it ...then do another section etc etc ... reason being you don't want to cut it all off or trim it off and risk panels coming apart with nothing left to clamp them back together ....good luck and post some pics when you're done

[DreKoushRanada]

There was a chevelle build on here ...kinda a stale build now but do a search of black widow chevelle.. It's a 70 and the owner Tim did trim/shave his and then ran a piece of round bar welded to it . Without going to the garage to look I'd say there is 3 layers (firewall, bottom of cool and top side of cool) minimum possibly more at the sides . So no matter if you trim it or not you will run into the spot welds along it , trim off an area and weld it ...then do another section etc etc ... reason being you don't want to cut it all off or trim it off and risk panels coming apart with nothing left to clamp them back together ....good luck and post some pics when you're done

Yes I know of the Black Widow build. I read all 23 pages of it. Kind of sucks that it did stall out like that. I hope he is well.

[DreKoushRanada]

I didn't like the first one I did. I decided to take my time on the template and do it over. This will go nice with the flush mount door handles and shaved drip rails. I am going to give 3m or similar panel adhesive a try for connecting the panels.
https://static1.pt-content.com/images/pt/2016/11/20161106_1734521_zpsd5ckes5i-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/20161106_1734521_zpsd5ckes5i.jpg.html)
https://static1.pt-content.com/images/pt/2016/11/20161106_1735321_zps3mllqm8c-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/20161106_1735321_zps3mllqm8c.jpg.html)

[csouth]

Looking good so far... I'd definitely be scared about moving the wiper motor, but that's just me...lol What door handles you going with?

[DreKoushRanada]

Looking good so far... I'd definitely be scared about moving the wiper motor, but that's just me...lol What door handles you going with?
The door handles are from a late model Buick La Sabre.

[DreKoushRanada]

Now to figure out how I'm going to fill the side marker lights. I think I will try the 3m panel adhesive. The last attempt ended with a warped fender. Good thing I had a spare to use.
https://static1.pt-content.com/images/pt/2016/11/20161106_174605_zpswroy7adw-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/Mobile%20Uploads/20161106_174605_zpswroy7adw.jpg.html)

[raustinss]

Have you tried the mechanism of the Buick handles ....and how the connect to the original Door latch ... I cut up an old Door trying to use gto/ catera handles which are quite similar in looks to the buicks . I'm just curious as to how you managed to do it. When I mocked up mine I tried to keep the handle in the stock location but wouldn't fit do to the inner structure of the door ,let alone trying to make new rods and pivots .

Firewall / cowl looks good . Any pictures of the shaved drip rails

[csouth]

Now to figure out how I'm going to fill the side marker lights. I think I will try the 3m panel adhesive. The last attempt ended with a warped fender. Good thing I had a spare to use.
https://static1.pt-content.com/images/pt/2016/11/20161106_174605_zpswroy7adw-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/Mobile%20Uploads/20161106_174605_zpswroy7adw.jpg.html)


Panel bond should work. Lots of body shops use is for repairs now days. I'm shaving mine too when the time comes.

[cpd004]

I'm tackling something similar and was looking into panel bond as well. Do you guys prefer a particular brand?

[DreKoushRanada]

Have you tried the mechanism of the Buick handles ....and how the connect to the original Door latch ... I cut up an old Door trying to use gto/ catera handles which are quite similar in looks to the buicks . I'm just curious as to how you managed to do it. When I mocked up mine I tried to keep the handle in the stock location but wouldn't fit do to the inner structure of the door ,let alone trying to make new rods and pivots .

Firewall / cowl looks good . Any pictures of the shaved drip rails

I have the whole doors still. I will be looking at the mechanism when I pull the old super dirty door latches. The ones from the donor doors are filthy and jam when I close the door. Here are a few pictures of the drip rails. The have been worked even more since taking these photos.
https://static1.pt-content.com/images/pt/2016/11/20161004_180457_zpskglyvefw-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/Camera/20161004_180457_zpskglyvefw.jpg.html)

https://static1.pt-content.com/images/pt/2016/02/20160224_160026_zpsgs7lmolm-1.jpg (http://s1064.photobucket.com/user/dholmes1/media/Mobile%20Uploads/20160224_160026_zpsgs7lmolm.jpg.html)

[raustinss]

Sounds good love to see how you do it being as I might just have to copy it.... Oh also when you do figure it out make sure you test it with the glass in , thought I had mine figured out but then the glass would have been in the way ...cheers

[DreKoushRanada]

Sounds good love to see how you do it being as I might just have to copy it.... Oh also when you do figure it out make sure you test it with the glass in , thought I had mine figured out but then the glass would have been in the way ...cheers

I am glad you mentioned that. It would of slipped my mind for sure.

[raustinss]

So did you leave a little lip so to say to help direct any rain or dew that may drip onto their window ....or is it a clean smooth shave ...lol sounds dirty

[DreKoushRanada]

So did you leave a little lip so to say to help direct any rain or dew that may drip onto their window ....or is it a clean smooth shave ...lol sounds dirty
I will grab a better picture tomorrow. I didn't leave any lip. I took it all the way down. I worked about six inches at a time. The step you see in the photo is the natural body line the car came with. Now I have to figureout how to mount these sport mirrors.