Re: How should I fill firewall holes
 

nuthin wrong with that, it cleans it up really nice, as long as it doesn't rub or rattle it's all good.
your truck,your idea, you're good with it. thats what counts.

Re: How should I fill firewall holes
 

I wanted an overall clean, smooth look so I did a steel overlay. As the pictures show, no welding was involved. I resisted "gluing" them on but a couple experienced bodymen convinced me that it was the way to go due to no warpage and minimal finishing associated with the process.

Fitting poster board templates

https://scontent.ffcm1-2.fna.fbcdn.n...35&oe=5A6CE4A6

After prepping I used 3M panel bond adhesive to attach the 18 gauge sheet metal panels.

https://scontent.ffcm1-2.fna.fbcdn.n...46&oe=5A854AA3

Edges beveled and blended with filler.

https://scontent.ffcm1-2.fna.fbcdn.n...68&oe=5A6B1A4F

Primed and painted...

https://scontent.ffcm1-2.fna.fbcdn.n...09&oe=5A82D8F7

I'm really happy with the end result

Re: How should I fill firewall holes
 

Very cool. I like the edge blending around the firewall cut out. I was planning on doing some work last weekend on mine and ended up slicing my hand open drilling some sheet metal. :Own:

Life lesson: Don't hold onto a stationary thing while using a spinning thing.

Re: How should I fill firewall holes
 

If you know an electrician with a toolbox, he probably has a whole bunch of 1/2", 3/4", and 1" KO punch outs from metal boxes. Those work good too for larger holes. or just buy a few metal boxes from HD or lowes and take em out yourself.

Also roofing nails work good for small holes - they have a BIG head....

Re: How should I fill firewall holes
 

just try to get the knock outs that are plain metal, not zinc coated.

Re: How should I fill firewall holes
 

Haha, I had some outside and ran out to check...dang it zinc.

Re: How should I fill firewall holes
 

it is just plating so you could always sand/grind it off if you need to.

Re: How should I fill firewall holes
 

borrowed from another thread, just throwing the link in here for a future couch mechanic

Hole fill kit

https://www.bobdrake.com/FordItem.aspx?Item=HR-1580

Re: How should I fill firewall holes
 

How about bead rolled firewall filler panels from LS Fab? $140 and give a super clean and custom look to the engine bay. Instruction available on the website to help with the install and can be used a replacement panel or put over top the original firewall if wanted.

Re: How should I fill firewall holes
 

If you want the stock look, and are not afraid of work,
Drill hole with step drill to get it round and a normal size you can buy filler plugs for
Clean area around hole to bare metal for a good weld
Buy some "unholes" from welders series online
Hold in with a magnet till tacked. Magnets distort weld so take them off asap
Weld plug in after racks completed in 4 spots around the circle
Beware of heat build up and distortion caused from that. If you have a helper have them hold a dolly on the backside while still smoking from the weld. Then hammer the weld a few times to help with the shrinkage caused from the weld heat/cool.

Or, glue a larger plug on the backside and then fill the void with bondo if you dont have a welder

Re: How should I fill firewall holes
 

I just made my own with snips and a bench grinder. you can weld a piece of wire hanger to the middle to get a hold of those small ones and magnets for the bigger ones. This is the area I started on to teach myself how to spot weld. A little bit of Rage gold and you are done. It takes a while but it wasn't too bad. I put blue tape over all the holes I knew I would be reusing so I didn't get carried away lol and filled up the rest.