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Author Topic: Firewall and cowl replacement FINAL  (Read 1970 times)

Offline miketyler

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Firewall and cowl replacement FINAL
« on: May 29, 2005 - 08:09:58 PM »
I got a donor top cowl and firewall section to replace the damaged sections on my car. I am going to seperate the donor top cowl from the firewall so I can bead blast and treat them in and out. the only section of my original firewall I plan to keep is in the area of the AC and its cutouts. I may cut mine out and weld into the donor firewall.

This is going to be pretty entailing and will include removing the windshield & detaching the inner fenders from the existing firewall. The front door posts would remain connected to the A pillar supporting the front of the roof.

Has anyone done this before? Was wondering if there are any details I am missing or popular misconceptions in doing this type of surgery.
« Last Edit: June 21, 2005 - 09:06:29 PM by miketyler »
72' Cuda restomod
70 Mustang Mach 1
07' Toyota Tacoma Prerunner Dbl cab in Speedway Blue!
01' Honda 1100 Shadow Sabre
96' Seadoo Challenger

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Firewall and cowl replacement FINAL
« on: May 29, 2005 - 08:09:58 PM »



Offline Steve

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Re: Firewall and cowl replacement Part II
« Reply #1 on: May 30, 2005 - 09:08:06 AM »
You're facing a big job there. Depending on where your rot is at and the level of your welding skills, you might consider cutting out the rusted areas and butt-welding in the donor metal. The other route has you drilling spot welds for 2 days. I personally would just replace what was rotten as opposed to swapping the whole assembly.

Offline dilligaf

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Re: Firewall and cowl replacement Part II
« Reply #2 on: May 30, 2005 - 10:44:17 AM »
Mike,
I think you saw the pictures of how I totally disassembled my 1974 Cuda.
It will all come apart like Steve says, I drilled out every spot weld.
Would not wish that on anyone to have to go as far as I had to on mine.
If I had to do it again (which I will on my other 1974) I will only replace what has to be replaced.
It is not necessary to replace a whole panel, to get rid of the rust, identify it, cut it out, make a piece and put it in, take lots, and lots of time welding it upp, smoothing it out, working it.
dilligaf
2 1974 'Cuda's
1 1973 Challenger

Offline miketyler

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Re: Firewall and cowl replacement Part II
« Reply #3 on: May 30, 2005 - 11:36:51 AM »
yes, I too would prefer a minimalist approach. The top cowl perhaps could be spliced but the inner cowl is rusted thru in the middle and at both ends. The passenger side has fiberglass repairs and a bondo/epoxy repair on the duct stiffener that looks like cake decorating.

The flat portions of the firewall are rusted thru outboard of the inner fender wells and of course the drivers side is rusted thru and has previous shade tree repairs as well

You are both right, I probably need to get an experienced second opinion and take advantage of any shortcuts I can. Patched or replaced, its going to be a big job but the latter would probably look better and last longer.   
72' Cuda restomod
70 Mustang Mach 1
07' Toyota Tacoma Prerunner Dbl cab in Speedway Blue!
01' Honda 1100 Shadow Sabre
96' Seadoo Challenger

Offline dilligaf

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Re: Firewall and cowl replacement Part II
« Reply #4 on: May 30, 2005 - 11:45:44 AM »
yes, I too would prefer a minimalist approach. The top cowl perhaps could be spliced but the inner cowl is rusted thru in the middle and at both ends. The passenger side has fiberglass repairs and a bondo/epoxy repair on the duct stiffener that looks like cake decorating.

The flat portions of the firewall are rusted thru outboard of the inner fender wells and of course the drivers side is rusted thru and has previous shade tree repairs as well

You are both right, I probably need to get an experienced second opinion and take advantage of any shortcuts I can. Patched or replaced, its going to be a big job but the latter would probably look better and last longer.
Mike,
Have you some good pics of the worst? I would like to have a look.
dilligaf
2 1974 'Cuda's
1 1973 Challenger

Offline Steve

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Re: Firewall and cowl replacement Part II
« Reply #5 on: May 30, 2005 - 12:30:33 PM »

You are both right, I probably need to get an experienced second opinion and take advantage of any shortcuts I can. Patched or replaced, its going to be a big job but the latter would probably look better and last longer.   

In my experience, it's easier to make the repair blend in and not be noticeable if you keep the spot welds intact. It's very tough and time consuming to replicate the look of the factory spot welds. When done properly, butt-welds blend nicely.

Offline miketyler

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Re: Firewall and cowl replacement Part II
« Reply #6 on: June 04, 2005 - 03:22:47 PM »
Well I thought it over and finally decided to let another guy handle the cowl and firewall replacement. I have too many other things that I could be doing and I would burn a lot of oil (and time) during the learning curve doing the metal work myself. I took it to him today and he agreed that with the damage was so spread out thst it made more sense to replace it as a whole. He is mulling it over so it might get spliced but right now he thinks it best to replace it all and then splice in the AC section.


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« Last Edit: June 04, 2005 - 03:58:44 PM by miketyler »
72' Cuda restomod
70 Mustang Mach 1
07' Toyota Tacoma Prerunner Dbl cab in Speedway Blue!
01' Honda 1100 Shadow Sabre
96' Seadoo Challenger

Offline miketyler

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Re: Firewall and cowl replacement Part II
« Reply #7 on: June 11, 2005 - 07:45:25 PM »
Got my car back today and overall am satisfied with the work. My guy is not a perfectionist but he has everything installed and has got it close enough for me to finish out. Will post pics soon
72' Cuda restomod
70 Mustang Mach 1
07' Toyota Tacoma Prerunner Dbl cab in Speedway Blue!
01' Honda 1100 Shadow Sabre
96' Seadoo Challenger

Offline miketyler

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Re: Firewall and cowl replacement Part II
« Reply #8 on: June 15, 2005 - 09:15:07 PM »
I got more pics and thought I would modify this thread so that it was chronologically corrrect. Submitted for your approval in...the Cuda Zone.

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« Last Edit: June 16, 2005 - 01:58:36 PM by miketyler »
72' Cuda restomod
70 Mustang Mach 1
07' Toyota Tacoma Prerunner Dbl cab in Speedway Blue!
01' Honda 1100 Shadow Sabre
96' Seadoo Challenger

Offline miketyler

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Re: Firewall and cowl replacement Part II
« Reply #9 on: June 16, 2005 - 05:00:12 PM »
and here are the latest pics showing the upper cowl stripped and ready for detial and final prime.
72' Cuda restomod
70 Mustang Mach 1
07' Toyota Tacoma Prerunner Dbl cab in Speedway Blue!
01' Honda 1100 Shadow Sabre
96' Seadoo Challenger

Offline miketyler

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Re: Firewall and cowl replacement Part II
« Reply #10 on: June 19, 2005 - 09:11:53 PM »
prepped and primed the engine bed Saturday, painted the inside, K-frame, and subrame today. Plum Crazy coming up next this week.
72' Cuda restomod
70 Mustang Mach 1
07' Toyota Tacoma Prerunner Dbl cab in Speedway Blue!
01' Honda 1100 Shadow Sabre
96' Seadoo Challenger

Offline 4Cruizn

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Re: Firewall and cowl replacement Part II
« Reply #11 on: June 19, 2005 - 09:44:01 PM »
Holy SH!T!! Those are some AWESOME pics!! Dammn!! :worship: :worship: :worship: Looks kind of strange with the firewall missing! :grinyes: Nice job!! :thumbs:
« Last Edit: June 21, 2005 - 09:09:18 PM by 4cruzin »

Offline Street_Challenged73

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Re: Firewall and cowl replacement Part II
« Reply #12 on: June 19, 2005 - 10:49:34 PM »
Wow, that was some intense work!!!  Glad it all turned out great for you, MikeTyler. :beer:
1973 Dodge Challenger......................The ongoing project. (00/----\00)
1991 Dodge Stealth R/T Twin-Turbo....The sunny day cruiser (RTBoost)
1990 Toyota Celica GT Liftback...........The new daily & winter driver.
All-American Muscle: 'Cudas and Challengers...Still the Elite and always will be.

                                                                                             
                 
Street_Challenged73 from Wisconsin

Offline miketyler

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Re: Firewall and cowl replacement Part II
« Reply #13 on: June 21, 2005 - 09:05:57 PM »
and so it goes......

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72' Cuda restomod
70 Mustang Mach 1
07' Toyota Tacoma Prerunner Dbl cab in Speedway Blue!
01' Honda 1100 Shadow Sabre
96' Seadoo Challenger

Offline 4Cruizn

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Re: Firewall and cowl replacement FINAL
« Reply #14 on: June 21, 2005 - 09:11:32 PM »
 :worship:   :worship:   :worship:   That is some flippin' fabulous work!!     :drool:  :drool:    Awesome job!   :thumbs:

Cuda-Challenger.com

Re: Firewall and cowl replacement FINAL
« Reply #14 on: June 21, 2005 - 09:11:32 PM »