So I was getting ready to jump into the metal work,and rust repair. Then a request for firewall fab popped up so thats where the metal work will start.
This is a pic of the stock firewall. It would have worked just fine like this,but it had alot of unnecessary holes. So we opted to build our own especially since we needed to build a tunnel and front floor pans. The pans on these trucks are removable panels,and someone forgot to put ours back before we bought it.
There is a bead roll on the stock firewall that we used as our cutoff point. Recessed the area by an inch and a half then made a cardboard template of the hole.
Transfered it to some 18 gauge. Did some bead rolls that would stiffen it up ,and also frame in the brake booster area.
The spot on the top right is for booster
We then made replacements for the missing floor panels. Looks tight but there is over an inch of clearance for trans.
That little bump was all I needed for clearance. In fact it could have been completely flat and been fine.
Here's the finished metalwork on firewall with booster installed. Nice,and clean only special tools used was a Woodward fab bead roller. About a days work to do including the floor.