Filling Chevelle firewall seam

[matty b]

hey on the 64 I wanna get rid of the wavy seam on the firewall and Im not sure how i want to attack this. Ive come up with two ideas, both include getting the seam sealer out. First idea is to spread some filler and feather it out. Thats the easy way out and if enough of you say no problemo on that Im gonna do that. Second way would be to cut the seam out and add in filler patches across it. I dont like this route just cause I dont like cutting original sheet metal out unless its damaged and cause you can end up with things getting misalighned, warped ect. I havent got the seam sealer out so tell you the truth i dont know if the mud route will even work( there maybe too much of a divit to do it correctly). Ideas please!!

[matty b]

nothin huh? nobody has cleaned up the firewall on a chevelle?

[danbob67]

well if you want to stay away from cutting the sheet metal you can get some fibral which is a fiberglass based filler and just use that first then go over with regular filler for the finishing. you can get a plate made to cover the whole face of the firewall then nothing really is disturbed if you use a panel bonding adhesive to attach it. Im just gonna weld mine on my camaro and weld the DSE heater box filler in and fill what ever else is needed to straighten it up same principle for the chevelle.

[matty b]

I think that would work using a full overlay panel didnt even occur to me and just weld it on. I just dont like cutting out huge portions of metal cause I get worried that things will shift. Thanks for the idea Illl keep everyone posted when the car gets ready for that

[MonzaRacer]

If I had my druthers i would make a plain sheet metal panel and weld it in over the whole firewall. If you have access to or can rent the use of a TIG welder you can get some great results blending in.
If this is too much get your self a gallon of Fiberglass Resin Jelly and several yard sticks.
Sand the yard sticks to round the edges, dont forget ti strip the old paint off it. Then rough it up with at least 220 or 180 grit wet and dry, if you can seal it with a coat of etching epoxy primer and then smooth it out, then ,after you either use a straight board or air file or sanding block and gett it flat. Then recoat with another coat of epoxy primer and then its ready for more paint detail.
This is pretty much a solid indestructable finish but can be damaged easier than sheet metal. BUT this is basicly fiberglass resin but will stay up like bondo but isnt porus like bondo. its completely water proof.
Dont cut anything out the seam is where the car is put together.
Good Luck
Lee

[Satatic]

On my 68 camaro i filled the seams with lead the best i could, filed, xpoxy, then bondo, then epoxy a few more times.

[41565 chevelle]

I am with danbob67. I have a 65 and that is what I plan on doing to the firewall...nice and smooth!

[shep]

I helped a buddy do this to the entire engine compartment on a fox body mustang. He welded all the small holes closed and made filer panels for the larger holes. After patching all the holes we used metal to metal putty and sanded it all smooth it looked awesome when it was done.