Should I weld up each individual hole or cut out large sections and weld in new sheet metal?
Do you think the firewall can be painted with the engine in place?

It really depends on just how smooth you want it to be. Keep in mind you are opening up a can of worms with this mod. Once you get started, there isn't an easy way to stop. If you smooth the firewall, then the inner fenders look bad. If you cover them, then the core support look like Swiss cheese. It never ends.

Ok, with that word of caution out there, I suggest you cut plugs for each hole and weld them separately. Cut a pattern for the inner fenders and make a cover piece for them.

You can paint it with the motor in, but it won't be easy, and the results will probably suffer.

just my 2 cents and how I am bulding my truck, they came from the factory ugly, that is how I am going to build it back. I do not plan to hide anything. where is your heater box, that will cover a lot

I'm not good with leaving things stock, I have the customizing disease. And for those who have not seen the rest of the truck it is pretty custom and shaved. I am in the process or redoing a lot.

looks good

looks like a burned spot on the hood and firewall. What happened?

Good observation! I nearly lost the whole truck and my house. Just after parking the truck in my garage one day an old fuel line between the fuel rails fell apart and caused a fire to start between it and the distributor. Since I was still standing out there talking to my father I noticed the smoke rising from the engine compartment. If I had just gone in the house I would not have known it was on fire. As you can see in the pics, the damage was minor compared to what it could have been. I ended up replacing the EFI harness, spark plug wires, distributor, coil, one injector, oh ya and the fuel line that caused it. I still need to get the paint fixed.

Keep in mind you are opening up a can of worms with this mod. Once you get started, there isn't an easy way to stop. If you smooth the firewall, then the inner fenders look bad. If you cover them, then the core support look like Swiss cheese. It never ends.

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Agree 110%! I had over 30 hours in a CORE SUPPORT once!!! :lol: Welded up every hole that wasnt used, filled every spot weld, ect... Then bolted the grille and headlights back in and covered everything up!