Firewall rust repair question

[tom999w]

Does anyone have any suggestions on how to tackle the firewall rust repair without replacing the whole firewall? I was thinking to buy a used firewall and cut it up and butt weld the good pieces where the rust was. But butt welding correctly is next to impossible to have the pieces butt together correctly with little to no gap, especially in an area like this which is hard to reach, in addition to having compound curves to match up. Or I've seen videos on the internet where people just fabbed a crude patch panel with a lip to butt against the floor board lip and tack weld it in. After all, it will all be hidden under the floor covering....

The yellow line indicates the lip where the new floor will be connected.

 

[gdrill]

Well, I’ll say that it looks like the firewall is not the first thing you need to repair. You better analyze that car closely. Frame rails and the side panel on the firewall appear to be in bad shape. Is it a special car?

 

[tom999w]

Well, I’ll say that it looks like the firewall is not the first thing you need to repair. You better analyze that car closely. Frame rails and the side panel on the firewall appear to be in bad shape. Is it a special car?

Ya, the frame, rocker, and floor are getting replaced. They're all in the process of getting removed/replaced now..

 

[MV8]

1/2 inch interior overlap of good, clean, weld-thru primed firewall, new sheet drilled to plug/spot weld into undrilled firewall, seam seal.

An air flange/punch tool is not that expensive.

 

[gdrill]

Wrong side of a border and too many state lines away equals lotsa miles! Nice car to build. Always better starting with as little rust as possible.

 

[matthon]

I had the same issue with the firewall and other areas on my 62 Dart, lower cowl was bad as well.
Thought it impossible to r&r a firewall.
First time welding and it wasn't that bad, better than multiple patches.

 

[tom999w]

1/2 inch interior overlap of good, clean, weld-thru primed firewall, new sheet drilled to plug/spot weld into undrilled firewall, seam seal.

An air flange/punch tool is not that expensive.

This sounds like a good way to fix it. I thought it would be better to use formed metal instead of flat sheet metal so located this firewall locally and will chop it up and patch up my firewall. Replacing the whole firewall was a good option too but when working on a rusty car you eventually have to draw a line of when to stop replacing panel after panel after panel...

 

[Oldmanmopar]

This sounds like a good way to fix it. I thought it would be better to use formed metal instead of flat sheet metal so located this firewall locally and will chop it up and patch up my firewall. Replacing the whole firewall was a good option too but when working on a rusty car you eventually have to draw a line of when to stop replacing panel after panel after panel...

View attachment 1716423438

looks like it came from a 1971 automatic, A/C, 2 speed wiper 340 car.

 

[matthon]

That car got t-boned. Nice solid car, too bad.

 

[matthon]

Without the help and encouragement of fbbo, and my stupidity to take on a complete rust bucket, I wouldn't have the welding 'skills' (grinding) I have now, and we completely dig this car now and thoroughly enjoy it.

Not saying every person should do this, just saying if a no experience, no business even attempting, guy can, then it's possible.

 

[4spdragtop]

@CFD244

 

[nutz]

looks like it came from a 1971 automatic, A/C, 2 speed wiper 340 car.

your amazing

 

[Oldmanmopar]

Without the help and encouragement of fbbo, and my stupidity to take on a complete rust bucket, I wouldn't have the welding 'skills' (grinding) I have now, and we completely dig this car now and thoroughly enjoy it.

Not saying every person should do this, just saying if a no experience, no business even attempting, guy can, then it's possible.

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62 plymouth ! Those were the days of my past. That is some nice work. I started out with Plymouths and then fell in love with the ugly Duckling Dodges. 62's and 63's.

 

[matthon]

It is a Dodge.

 

[CFD244]

@CFD244

LOL......I wouldn't do that again