Smoothing the 86 firewall

[86gmc23]

Tried using the forum search but didn't come across anything. Was wondering if anyone has a truck build who smoothed their firewall that posted on the site. Just trying to do a little research before I start hacking up my pickup. It has some rust that needs fixing so I figured I would go the extra mile and smooth it out. Any help would be greatly appreciated. Thanks.

[bake74]

     http://forum.73-87chevytrucks.com/smforum/index.php/topic,7175.150.html    Here is one example.  It is Vile's truck, the firewall is started on page 11.

[86gmc23]

Thank you, I knew I remembered seeing some on here. Thought it may have been one of Viles threads.

[VileZambonie]

There's some things you need to think about. How far do you want to go really. Some guys even eliminate the booster/master from the firewall. I cut out the tunnel and eliminated the seam as well as the shelf. Lots of cutting grinding and welding, remapping your wiring harness etc. My best advice is plan accordingly before you start cutting.

[86gmc23]

Really just wanting to clean it up. Not building show car, just custom. Im a welder buy trade so I figure cutting, grinding, and welding is no big deal. What thickness material used for firewall and what grade steel is common for automotive applications. Thanks for advice, right now I have $200 invested in truck so now is the time to mess it up or come out with something really cool.

[86gmc23]

Ok so im going to start planning for this. This is what I need consider, tell me if im missing stuff. Steering, brake booster n master, trans, electrical wiring, ac/heat. Want to keep master in stock location. As for ac, does vintage air have set up that goes under dash? No need for heat in FL so I can bypass that. Most be overlooking more. Sorry if I sound retarded, Im a welder/fabricator by trade but trying to get into automotive stuff so in this department im learning. Plannin on 18ga steel for new firewall. Any help would be awesome, will post pics when project gets underway. Thanks

[VileZambonie]

Yes for the AC unit you somehow need to get the liquid and vapor line out to the condesnsor and compressor. One thing you can do is route it low under the firewall on the pass side and build a secret compartment over the wheel well area to hide all of your wiring, lines, hoses etc. It's all in how far you want to go!

[86gmc23]

I can get full sheet of 16ga for $110 or sheet of 16ga for $75. Which should I get for cutting firewall out and putting in new one.

[bake74]

I can get full sheet of 16ga for $110 or sheet of 16ga for $75. Which should I get for cutting firewall out and putting in new one.

      You listed the same gauge.     The $75.00 one I would say.

[86gmc23]

Lol  meant to put the $75 one as 18gauge

[DnStClr]

With my welding skills, I'd use 16 ga.- wouldn't burn thru as easy..lol. 

[bake74]

     Question ?  Are you planing on putting in a complete flat sheet for a fire wall or are you going to "mold" it at all ?

[86gmc23]

Really just figuring it out as I go. Only tacking in place til i think its good. Going to cut the face of the firewall out and replace with smooth sheet of metal. Should that be ok with 16ga, I can add support to the inside if needed. Like I just before I'm learning as I go, this is my start up truck. I'm a welder by trade so I'm not worried about my welds. Plan to do quite a few body mods before anything else, that way if I screw it up I can just find a new truck. Picked up my metal today and went to start working on truck when I noticed my welder and few other power tools were missing, so now its on hold until I find them.(it was an inside job)

[Captkaos]

FlamingC10 did a smooth one also...

[86gmc23]

Found my tools at the pawn shop other day so decided I would start cutting out old firewall.

Got to fix inner structure then I can do firewall, hopefully will get all templates made this week so I can cut repair pieces this coming weekend.