Firewall flange removal

[Denee007]

I'm not even going to show you a photo of the start of my firewall ridge removal! I sectioned off about 6 or 7 inches, I used a cutoff wheel to make the section by cutting directly into it. Prior, I had sandblasted (aluminum oxide) the upper area. Looks like crap, the metal coming downward doesn't look too great.

I put a weld on the top portion (my weld burned through a bunch), but made it almost complete with the exception of a few pinholes.

I put a cutoff wheel on my angle grinder and cut off the rail that I have sectioned off. I welded that, if you want to call it welding. I'm actually a fair welder-er, but this is making me look BAD! Cutting the rail off does kind of leave a larger gap than I was contemplating.

I ground on that weld for quite some time, and now there are a few larger pinholes that I'm going to have to fill like smaller firewall holes.

I should jjjust (starting to studder!) weld a lip back on and call it a day!

After a well derserved cup of coffee, I'm sitting here recooping my strategy, of course with ya'lls help!

How about this, as difficult as it may sound, why can't I weld from inside the cab, at least 3/4's of it is accessible(I think). There's a perfect little "V" where the panels adjoin. However getting it clean for welding may be a pita. Plus access above where the steering column would be a pita too. Anyway, I could stand on the floor of my garage and work up through the floor panel fairly comfortably. I have a ventilation setup to suck out the smoke.

OTHERWISE~ advice would welcomed

[Kim57]

Denee
Pics would help. Don't be afraid to show your work.
Cutting the lip off flush with the fire wall can leave it a bit thin and make welding more difficult.
You may try leaving a very small lip. The new weld should penetrate and be deep enough so that when you grind it it should be fine.
Hope this helps.
Kim

[Denee007]

Ok, here are a few. The one with the engine kind of shows what I'm up against, just the area above the battery. I wont be able to do the entire firewall as the fender wells are in there and they're not coming out. So I'll be going up to the point where the hood hinges are. From the pic, looks like I need to do some more wire brushing.

[Kim57]

It looks like the top part is very thin already. I would try and cut down on the power on the welder or turn the speed up slightly and see if it helps to keep from blowing through.
Kim

[pgf545]

Denee, I would try to do multi passes also. Start on the top and lay down a row of spot welds and then do another row right under that one until you get to the lower panel. Kinda hard to explain on here but maybe that will help you some.

Bernie

[buggy5872]

Why are you cutting the lip off? I belive you ar taking a lot of the strength out of the front of the cab. That lip acts as a reinforcment for the firewall.

[_Ogre]

to make it look smoooth
you still have all three parts welded together, will probably make it stronger



denee: i agree with kim, it looks real thin on top from rust.
think seriously about shaving your cowl vent too, that's where the water and rust come from.
you can also weld the inner cowl and the firewall from the inside, it adds a little meat to the metal.
this pic you can see where the welding from the inside burnt the paint



other than thin metal, your doing it right. just keep welding until you find metal.
if it keeps burning back maybe a filler piece will be needed.

[Denee007]

Omg, don't ask me that now! The lip is gone!
I gave up for a few days, my low back is kind of getting to me, in fact I think I'll take the week off to recooperate! Crawling in and out of the engine compartment is getting to me, yall know how it is! Plus I wish I hadn't put the engine supports in, I have two gashes on my low back from hitting those darned things! I actually may have to enlarge the long rectangular hole that I made, the weld looks aweful! I see daylight everywhere!

Anyway, this is where I Left off. Metal had to be removed due to corrosion from the battery/rust. I initially welded the entire seam from inside the cab and yes, it was a pita, but I think it worked out well. However, I wound up removing a lot of it as the pics show. I may have to start all over and find better metal on the cab. The doner metal came from an unused floorpan. It was a crappy USA made piece, very poor construction, I dont even think it was as thick as it should have been either! be nice ok? ; )
Oh, this is about when I found out my c25 gauge was flowing too much gas, the ball was pegged, I must have turned it somehow! I'm using .025 wire on my 135 amp mig.
Ps: if this is how well my radio patch panel is going to go, Im going to be in big trouble!!!!

Originally Posted by buggy5872

Why are you cutting the lip off? I belive you ar taking a lot of the strength out of the front of the cab. That lip acts as a reinforcment for the firewall.

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[Kim57]

Denee
You're doing fine. Just take your time and it will be fine.
I know what you mean by having to take some time away to get the motivation back.
Kim

[_Ogre]

6 bolts and the whole front clip comes off
makes life in the engine bay a lot easier too

seriously? looks fine, welding thin rusty steel is never fun.

[pgf545]

If you are crashing into stuff sticking out like the motor mounts I like to wrap a towel or a wad of rags around the offending parts and tape it up. That should help with the scrapping but if you hit it hard it still hurts like hell.....lol.

Bernie

[OrrieG]

I use old milk jugs, especially on exposed frame rail ends. Don't worry about the welds that is why we have grinders!
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[Denee007]

Well, I'm right on track then! As far as jabbing my back, good idea, I'll wrap a towel around each engine supports! ( good idea!) I kept thinking ,"I'll be more careful" ha ha, then I'd get in a little hurry and WHAM! Lol
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[oldcouple]

I wear a knit cap as well, amazing how many times you can bump your head, the little bit of extra cushion helps.