47-59 Firewall Swiss cheese-What to do

[Bridgeman57]

After getting my frame, firewall, under cab blasted. Motor, tranny, t case installed. Not moving forward with the build. Trying to decide what to do with the firewall. A lot of small holes and larger ones. Don’t have the money to get it professional done. Can maybe do myself but don’t have the proper machine to punch the larger holes. Evilest sales a firewall panel that I can have a buddy bolt in on the cheaper side. Basically covering up the holes.
Anybody got a better idea or would this be acceptable by any means? Or would just putting some good material inside the cab solve the issue of heat/ fumes entering the cab? That’s the only concern.

Thank y’all
I’m ready for the beating up From you guys 👍🏻
I know it’s not solving the long term problem. But on the bright side I’ll most likely rebuild this truck twice in my life anyways. I am only 26 and have nothing but time. Not so much money for it yet

[Rickysnickers]

Do you have a welder or access to one? If so, it would be a great time to learn how to weld up those holes.

[Bridgeman57]

Here it is

[Bridgeman57]

Unfortunately I have painted some kbs on here already but not to worried about removing it

[Bridgeman57]

I do have a welder and know how to weld but not sure I can do the bigger holes myself

[notsolo]

I glued..( polyurethane caulk) a piece of 1/8" aluminum over the old brake booster hydraulic clutch holes.....polyurethane caulk around the edges and painted. Helps if the swiss cheese is flat.

[58CameoAZ]

Originally Posted by Bridgeman57

Here it is

that looks "WAY" Better than my firewall did, previous owner took a 56 ford heater and Bazooka'd my firewall getting it to fit!

I would say save your pennies and buy yourself a Welder with shielded gas
would be my first suggestion and learn how to weld the holes up yourself!
not that hard.

Or, Take it to someone that can weld the holes you don't need.

I got my truck when i was 16, and i am 59 so, Yes, you can build it many times threw the course of your life, along the way i saved and bought part and tools to do the work myself and it is very more rewarding to do it and learn yourself
,just my 2cents

Good luck with your Truck,
Allen

[58CameoAZ]

Originally Posted by Bridgeman57

I do have a welder and know how to weld but not sure I can do the bigger holes myself

What kind of welder? Mig with 0.23 SOLID Wire and Gas shielding work the Best, Just stitch the holes and you can back the small ones up with Brass as you plug weld the holes.

wish my firewall looked as good as yours, I counted over 200 Holes in the Cab,
I think the PO Got a New Drill for Christmas and tested it out on the Cab, LOL...

Allen

[Bridgeman57]

I got an Eastwood 135. Not the greatest welder but it was free👍🏻 Running 0.35 right now. Never tried 0.23. Will go buy some. Yes the cab is in beautiful condition minus some dents on roof and cab corners but only one small rust spot on lower inner pass side of cab. Very thankful for A rust free truck
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[mr48chev]

Find some scrap sheet metal the same thickness (Junk hood, door, fender and cut some pieces out of it and practice welding them back in. You don't even have to cut it clear out just cut a slot, clean the metal around it with a flap wheel and weld it back together until you figure out the settings and gain a bit of confidence.

The one screw up that happens all the time is that guys try to weld too long a bead in one spot and end up warping the metal. Very few of us can honestly say that we have never done that on a rig at one time or another. It's called learning experience but you can also learn from those of us who have already made that mistake and just put short tack welds around the patch, let it cool and tack some more.

LS Fab makes some nice bead rolled panels but they aren't all that cheap. https://lsfab.ca/product-category/5559/

[MiraclePieCo]

Filling all those holes is an exercise in masochism. I cut out most of my firewall and filled it with flat 16-gauge sheet. Hey, I'm not Chip Foose: I'd rather be driving my truck than spending a month filling holes that no one will ever see, especially with a firewall-mounted battery and brake booster.

[Black_Sheep]

I cut overlay panels from 18 gauge steel and attached them with 3M Panel Bond adhesive. With a small amount of filler to blend the edges it was good to go.

[MiraclePieCo]

Originally Posted by Black_Sheep

I cut overlay panels from 18 gauge steel and attached them with 3M Panel Bond adhesive. With a small amount of filler to blend the edges it was good to go.

Nice!

[mr48chev]

Very nice indeed. I've got a sheet of aluminum that I snagged at my friend's scrap yard (had to pay full bore, no buddy deals) that is held on mine by screws to cover up my mistakes. That was put on pre panel bond though.

[59chev]

Unholes from Welder Series for the larger holes. Drill each hole out to the appropriate size with a step bit and weld them in.. Any of the smaller holes I just put a magnetic copper backer behind it and buzzed them shut.

https://welderseries.com/Unholes-p50202282

[mick53]

You can get things like these unholes.
https://welderseries.ecwid.com/Unholes-p50202282

[_Ogre]

that's one of the cleanest cabs i've seen to date. i don't see rusted front corners or hinge area holes. all of us that smoothed firewall had to deal with those holes.

i bought some 1" strip sheetmetal from home depot and cut it into squares. placed inside the cab, welded outside. finished product looked a lot like 59chev pic. bigger holes i cut sheetmetal with 4" grinder. small holes just flatten a chunk of 3/4" copper pipe and hold it against the inside, weld won't stick to copper or brass

if your using .35 welding wire, it is fluxcore, .23 is solid mig wire for use with gas. i welded most of my truk with fluxcore, it just requires more grinding.

[LEEVON]

I filled a majority of the holes on my firewall with electrical box knock-outs I picked up on jobsites. I made the holes fit with a step bit, held the knock-out circles with a magnet on the backside, and welded them up. Some of them I didn't want to make the holes larger so I basically "plug welded" the holes with the knockout on the backside. Looks great, easy peasy.

[jweb]

I did the firewall on my '51 the same as Miraclepie showed above, using 2 flat pieces.

On my current project I got these to fill in different size holes:
https://www.bobdrake.com/FordItem.aspx?Item=HR-1580

[Bridgeman57]

Awesome thank you all. Will update when I figure it. I’m at the point of wanting to rush and get driving but part of me wants to get the cab 100% dialed in so later I won’t have to worry. Still have to take cab off frame, windows out, doors off. Which is were my dilemma is. Go all in or save money and time!? Killing me. Will just do it right 15 years from now! 😂👍🏻
Have been told by many ppl that it’s the best cab they’ve seen in 20 years. That’s why I want to preserve it.
The paint is in okay condition. It looks original but somebody sprayed over it one day.
What to do, what to do

[GeronimoApache]

New vendor here sells these. Probably be a lot faster for you.

https://ls-fab.com/product/1955-1959...lled-firewall/

[Khaus]

I had the same dilemma and went with some firewall panels, toe boards and upper cowl filler. Turned out great and ultimately was the start to our company where we now offer them along with many other products.

www.ls-fab.com

[Dongray]

Leevon, I noticed you filled the pedal holes as well. I was curious what type of pedals you would be switching over to. I would like to use something different but am hesitant about my skills for hooking up different linkage.

Thanks!

[my56chevytruck]

Originally Posted by 58CameoAZ

that looks "WAY" Better than my firewall did, previous owner took a 56 ford heater and Bazooka'd my firewall getting it to fit!

I would say save your pennies and buy yourself a Welder with shielded gas
would be my first suggestion and learn how to weld the holes up yourself!
not that hard.

Or, Take it to someone that can weld the holes you don't need.

I got my truck when i was 16, and i am 59 so, Yes, you can build it many times threw the course of your life, along the way i saved and bought part and tools to do the work myself and it is very more rewarding to do it and learn yourself
,just my 2cents

Good luck with your Truck,
Allen

Seeing his firewall I was about to say exactly what you did. My firewall appeared as though they used it for target practice. Aside from that, I removed my firewall and replaced it completed with a new panel.