55-59 Firewall Replacement - The 1947 - Present Chevrolet & GMC Truck Message Board Network

dwcsr · 09-13-2009, 10:32 PM

I just finished replacing a firewall on a 56 and thought I would share the info. The idea was to clean up the firewall and smooth out the upper section. The owner wanted to get a premade firewall that was recessed but cost was a big factor in they way we did this one. As you can see the original was very damaged from a clutch explosion and far beyond repairing. We priced a firewall and floor section at about $675 plus about $150 in shipping. We also priced a sheet of 16 gage 4'X8' @ $38.00. We went with the 4x8 sheet.

The pictures that follow are fairly self explanitory but I'll fill in where I think some detail is needed.

We made a cardboard template that fit the way we wanted the completed firewall to look. Using a hot glue gun to attach the various pieces and firm up the model made it much easier.

dwcsr · 09-13-2009, 10:33 PM

With the model done we removed it and cut it apart where we wanted the folds and cuts to be. The technique we used to do the bends on 16 ga without a brake was making cuts along the bend lines with a plasma torch. The .030 slits were easily welded up when we were at that point. At each bend point we made a cut 1" long a 1/4" from the end and followed that pattern of 1" 1/4" all the way to the end of the bend.

dwcsr · 09-13-2009, 10:35 PM

We bent the panel into place by hand and proceeded to the next panel.

dwcsr · 09-13-2009, 10:36 PM

We cut out and tacked in place the other pieces just like a puzzle.

50adrod · 09-13-2009, 10:39 PM

nice work, you have to love plasma cutters.

dwcsr · 09-13-2009, 10:41 PM

Next we bent the toe boards into place.

dwcsr · 09-13-2009, 10:46 PM

We trimmed out the original toe boards filled in the toe area. All thats left it to mate up the toe to the original floor.

dwcsr · 09-13-2009, 10:50 PM

We didn't cut out the lip that goes around the firewall we will use a 2" strip of the original firewall we left in plce to weld the new firewall to. We left enough all the way around to put plenty of rosette welds and not have to disturb the original spots welds. We end up with a very flat smooth firewall.

CAL 58 GMC · 09-14-2009, 10:40 PM

Nice job on the firewall! But I have to ask, how did the old firewall get so banged up?

dwcsr · 09-15-2009, 12:20 AM

Quote:

Originally Posted by CAL 58 GMC

Nice job on the firewall! But I have to ask, how did the old firewall get so banged up?

Thanks,,
From what I was told the clutch exploded during a drag race. I have only heard about flywheels coming through the bell housing and the damage it can cause but never seen the actual results until now. I'm sure there was an equally large brown spot under the driver seat when it happened.

ChuckDriver · 09-16-2009, 09:08 AM

Looks awesome!

OrrieG · 09-16-2009, 11:23 AM

Quote:

Originally Posted by dwcsr

Thanks,,
From what I was told the clutch exploded during a drag race. I have only heard about flywheels coming through the bell housing and the damage it can cause but never seen the actual results until now. I'm sure there was an equally large brown spot under the driver seat when it happened.

When I was 18 we hand grenaded a clutch in a 55 Chevy (built 327, Muncie 4 speed). I was riding passenger. BIG bang and the windshield exploded. It had 3 holes in the top of the dash, schrapnel in the radio and heater and multiple holes in the floor boards. We were lucky that it missed our feet. We tossed the aluminum bellhousing. After that when guys started reving them up I would pull my feet up unless I was driving.

dwcsr · 09-16-2009, 04:55 PM

Maybe the NHRA had the right idea on bell housings.
I don't remember who but a famous Top Fuel driver lost part of a foot like that back when the engines were in the front of the driver.

MrSinister · 09-17-2009, 01:27 AM

love the cab dolly think I know what I'll do with the scrape frame in my backyard

dwcsr · 09-17-2009, 01:31 PM

Quote:

Originally Posted by MrSinister

love the cab dolly think I know what I'll do with the scrape frame in my backyard

It worked out perfectly. I would use solid wheels next time the same size.
Once the cab is bolted down you can replace just about anything and be sure it hasn't sprung out of place.

OrrieG · 09-17-2009, 05:24 PM

Quote:

Originally Posted by dwcsr

Maybe the NHRA had the right idea on bell housings.
I don't remember who but a famous Top Fuel driver lost part of a foot like that back when the engines were in the front of the driver.

Don Garlits, first to run rear end AA/F because of it.

46deluxe · 09-20-2009, 10:55 PM

Quote:

Originally Posted by OrrieG

Don Garlits, first to run rear end AA/F because of it.

You might want to double check that Garlits was the 1st. the Kaiser Bros., Bernie Schacker, Duane Ong, Duane Ong won an AHRA event with a Woody Gilmore car before Garlits built his. No doubt of the clutch explosion and the damage done

dwcsr - Firewall looks great.

09-13-2009, 10:32 PM	#1
dwcsr Hollister Road Co. Join Date: Apr 2005 Location: Houston Posts: 6,134	55-59 Firewall Replacement I just finished replacing a firewall on a 56 and thought I would share the info. The idea was to clean up the firewall and smooth out the upper section. The owner wanted to get a premade firewall that was recessed but cost was a big factor in they way we did this one. As you can see the original was very damaged from a clutch explosion and far beyond repairing. We priced a firewall and floor section at about $675 plus about $150 in shipping. We also priced a sheet of 16 gage 4'X8' @ $38.00. We went with the 4x8 sheet. The pictures that follow are fairly self explanitory but I'll fill in where I think some detail is needed. We made a cardboard template that fit the way we wanted the completed firewall to look. Using a hot glue gun to attach the various pieces and firm up the model made it much easier. Attached Images

09-13-2009, 10:33 PM	#2
dwcsr Hollister Road Co. Join Date: Apr 2005 Location: Houston Posts: 6,134	Re: 55-59 Firewall Replacement With the model done we removed it and cut it apart where we wanted the folds and cuts to be. The technique we used to do the bends on 16 ga without a brake was making cuts along the bend lines with a plasma torch. The .030 slits were easily welded up when we were at that point. At each bend point we made a cut 1" long a 1/4" from the end and followed that pattern of 1" 1/4" all the way to the end of the bend. Attached Images Last edited by dwcsr; 09-13-2009 at 10:52 PM.

09-13-2009, 10:35 PM	#3
dwcsr Hollister Road Co. Join Date: Apr 2005 Location: Houston Posts: 6,134	Re: 55-59 Firewall Replacement We bent the panel into place by hand and proceeded to the next panel. Attached Images

09-13-2009, 10:36 PM	#4
dwcsr Hollister Road Co. Join Date: Apr 2005 Location: Houston Posts: 6,134	Re: 55-59 Firewall Replacement We cut out and tacked in place the other pieces just like a puzzle. Attached Images Last edited by dwcsr; 09-13-2009 at 10:39 PM.

09-13-2009, 10:39 PM	#5
50adrod Registered User Join Date: Jun 2008 Location: Louisiana Posts: 493	Re: 55-59 Firewall Replacement nice work, you have to love plasma cutters. __________________ 1971 Corvette convertible 454@ 525 hp 1936 Chevy Truck street rod 1952 Chevy truck hot rod build http://www.killbillet.com/showthread...2-Chevy-Cut-up 1964 F 100 custom street rod http://www.ford-trucks.com/forums/12...mark-viii.html 1950 custom Chevy Truck

09-13-2009, 10:41 PM	#6
dwcsr Hollister Road Co. Join Date: Apr 2005 Location: Houston Posts: 6,134	Re: 55-59 Firewall Replacement Next we bent the toe boards into place. Attached Images

09-13-2009, 10:46 PM	#7
dwcsr Hollister Road Co. Join Date: Apr 2005 Location: Houston Posts: 6,134	Re: 55-59 Firewall Replacement We trimmed out the original toe boards filled in the toe area. All thats left it to mate up the toe to the original floor. Attached Images

09-13-2009, 10:50 PM	#8
dwcsr Hollister Road Co. Join Date: Apr 2005 Location: Houston Posts: 6,134	Re: 55-59 Firewall Replacement We didn't cut out the lip that goes around the firewall we will use a 2" strip of the original firewall we left in plce to weld the new firewall to. We left enough all the way around to put plenty of rosette welds and not have to disturb the original spots welds. We end up with a very flat smooth firewall.

09-14-2009, 10:40 PM	#9
CAL 58 GMC Senior Member Join Date: Jun 2005 Location: Clovis Ca. Posts: 3,311	Re: 55-59 Firewall Replacement Nice job on the firewall! But I have to ask, how did the old firewall get so banged up? __________________ Classic Trucks Link http://www.classictrucks.com/feature...uck/index.html 1958 GMC.Project Build http://67-72chevytrucks.com/vboard/s...d.php?t=162816 1966 Chevelle Build http://67-72chevytrucks.com/vboard/s...d.php?t=443576 Video http://www.youtube.com/watch?v=prrNKo8F7Zw#GU5U2spHI_4

09-16-2009, 09:08 AM	#11
ChuckDriver A320 Pilot/USAF Retired Join Date: Mar 2009 Location: Charleston, SC Posts: 2,622	Re: 55-59 Firewall Replacement Looks awesome! __________________ JJ My 1957 build: http://67-72chevytrucks.com/vboard/s...d.php?t=334552 http://www.trifive.com/forums/showthread.php?t=22037 Instagram - Chuckdriver57

09-16-2009, 04:55 PM	#13
dwcsr Hollister Road Co. Join Date: Apr 2005 Location: Houston Posts: 6,134	Re: 55-59 Firewall Replacement Maybe the NHRA had the right idea on bell housings. I don't remember who but a famous Top Fuel driver lost part of a foot like that back when the engines were in the front of the driver.

09-17-2009, 01:27 AM	#14
MrSinister Registered User Join Date: Mar 2007 Location: Everett Wa Posts: 70	Re: 55-59 Firewall Replacement love the cab dolly think I know what I'll do with the scrape frame in my backyard __________________ '56 Big window 350/700r4 9" rear w/disc



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