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Old 11-15-2017, 10:35 PM   #1
MiraclePieCo
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Join Date: Sep 2014
Location: USA
Posts: 2,249
20 small holes or 1 big hole?

When I bought my truck I was thinking, "Great, someone already filled the firewall." Yeah, with bondo. I spent the day knocking out the bondo plugs with a hammer (yes, including the 4" heater motor hole!). Now I have about 50 holes to fill.

My question is: It seems vastly more efficient to cut out big panels and fill with a single piece than try to meticulously fit 25 small plugs. Again, see pics: I have outlined where I plan to cut and patch with fresh metal. Alternately, I could just cut out the panels and overlap with fresh metal, either welding or bolting the edge to the remaining lip of original metal.

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