Smoothed Firewall Questions

[John510]

How did you guys shave your firewalls? I dont want to use the DSE plate since I want it completely flat with no seam. Maybe just one big piece of sheetmetal and cutout the holes I need?

[ProdigyCustoms]

We butt weld 16 gauge sheetmetal, and weld the seam up solid using staggered stitch welding.

[eville]

We butt weld 16 gauge sheetmetal, and weld the seam up solid using staggered stitch welding.

No picture now, but that's how we did mine.

Welded the seam, uneeded holes and filled the heater box hole w. 16 ga.
Looks good.

[John510]

Should the old firewall be removed or just weld over it?

[ProdigyCustoms]

Remove the old or you will have a vibration nightmare.

[syborg tt]

i did the firewall on my truck 3 different way's.

1st way was to just remove the old ac box
2nd way - try to smooth it a little more

3rd way - way exactly like i wanted it

scroll down
https://www.pro-touring.com/forum/showthread.php?t=10772&page=27

[Overkill]

I made little fillers on mine and welded them in to the blower motor and heater core holes along with the windshield wiper hole since I moved it inside the cowl. I also welded in smaller pieces of metal in to the bolt holes and any other hole that was in the firewall that I wasn't going to need. I had to straighten out the lip around the heater core hole with vice grips, a body hammer and dolly. Once I had the pieces in and ground smooth, I skim coated with body filler. I left the line between the firewall and cowl section because I think that a totally smooth firewall looks a little bland to me.

https://static1.pt-content.com/images/pt/2008/03/camaro_rebuild232-1.jpg

https://static1.pt-content.com/images/pt/2008/03/camaro_rebuild233-1.jpg

https://static1.pt-content.com/images/pt/2008/03/camaro_rebuild235-1.jpg

https://static1.pt-content.com/images/pt/2008/03/camaro_rebuild237-1.jpg

https://static1.pt-content.com/images/pt/2008/03/camaro_rebuild248-1.jpg

Wiper motor hole:
https://static1.pt-content.com/images/pt/2008/03/camaro_rebuild249-1.jpg

Body filler before sanding:
https://static1.pt-content.com/images/pt/2008/03/camaro_rebuild250-1.jpg

Finished and painted: (seam sealer dried a little to quickly so It's a little rough, but not bad)
https://static1.pt-content.com/images/pt/2008/03/camaro_rebuild273-1.jpg

[Terry Hubbard]

Hey guys, this is my first time to post and I may be to late, but attached are several pic of smoothing the firewall on my 68. I also had to modify my tranny tunnal for a T-56 as well as make it look a little better. To cut down on vibration, I welded in several places through the existing firewall to the new one to tie them together.
https://static1.pt-content.com/images/noimg.gifhttps://static1.pt-content.com/images/pt/2008/03/DSC01305-1.jpghttps://static1.pt-content.com/images/pt/2008/03/DSC01306-1.jpg

[Terry Hubbard]

https://static1.pt-content.com/images/pt/2008/03/DSC02338-1.jpg
https://static1.pt-content.com/images/pt/2008/03/DSC01292-1.jpg

[wwolfe]

looks nice....did the same to mine