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Firewall rust repair

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Old Oct 25, 2018 | 11:19 PM
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Firewall rust repair

Looking for recommendations or feedback on this repair... my plan is basically to cut out the bad spots and graft in some new material. Anything I should consider?

yes the cab is on its back.
 
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Old Oct 25, 2018 | 11:23 PM
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Yay I did it... finally got these to post!
 
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Old Oct 27, 2018 | 10:51 AM
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Bumping... finally got pictures attached.
 
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Old Oct 27, 2018 | 10:57 AM
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I did an extensive repair on my build. You can see it on the build thread below. The repair starts on post #120 on page 8. Let me know if I can answer any specific questions. The only thing I'd change is that I'd make the top piece on my shrinker/stretcher, but I didn't have one at the time.
Build thread
 
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Old Oct 27, 2018 | 12:37 PM
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Thanks for all that. I think the sealant does more harm than good. My guess is it’s letting water puddle in there. I might reseal mine on the forward side of the firewall when done so if water does get in it can simply drain.

I hadn’t taken of the bad parts out yet so and assumed the firewall was tacked to the cowl. It helps knowing the dash is sandwiched in there. I will post more pics as this progresses.
 
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Old Oct 27, 2018 | 09:36 PM
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Got a bit done one this. Removed the support on the drivers side. Marked out where the firewall will be cut. Drilled pilot holes on all the spot welds I could identify. Will try to get this section removed tomorrow.

My ability to upload photos seems to be intermittent. Will upload more as I can.


 
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Old Oct 28, 2018 | 01:38 PM
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So in an effort to save some time I am wondering if firewall sections and the forward dash sections are available to purchase anywhere. I looked at LMC, NPD, EBay, and a few other places and nothing turned up. I can repair what I have but said repairs are growing in size and extent the further I get into the disassembly. Thanks!

 
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Old Oct 28, 2018 | 02:21 PM
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This comes in handy... $5 at harbor freight. I did about 2 dozen welds with this.



 
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Old Oct 28, 2018 | 10:21 PM
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Well finding replacement sections is probably just wishful thinking. So repairing what I have is underway.

Removed the rusted firewall section




And found more rot rot on the dash section so I removed that as well




And I should be done removing rot. Next step is to clean up the cuts and prep the patches. Fortunately I shouldn’t have to remove the dash.
 
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Old Nov 12, 2018 | 07:54 PM
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Starting small...



 
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Old Nov 12, 2018 | 07:56 PM
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The center piece of the dash is ready to install.




 
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Old Dec 26, 2018 | 10:42 PM
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A bit of progress. Not pretty but no holes. The forward dash is only about 0.040” thick. All it wanted to do was warp when it wasn’t burning through.


 
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Old Dec 26, 2018 | 10:43 PM
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And some work on the firewall as well. Much easier to work with.
 
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Old Dec 27, 2018 | 12:18 AM
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That's some pretty intricate surgery!
 
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Old Dec 27, 2018 | 07:57 AM
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Yeah fortunately this will be very hard to see once everything is back together. Functionally this will be solid. Aesthetically, it could be better. This is a matter of balancing the benefits of the aforementioned concerns... I would take a lot more effort than it’s worth to make this look unrepaired.
 
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