Firewall Project

pro70z28 · 10-23-2009, 10:12 PM

I'm ready to rebuild the firewall. I cut the flanges out today for the intercooler tubes to pass through the firewall. I'll turn them down on the lathe & weld them in place & shape the sheet metal around them.

pro70z28 · 10-25-2009, 07:36 PM

Got the flanges turned this weekend.

I put a groove around the edge of the flange for the firewall sheet metal. Once I install the o-ring and get in place I'll check the new gap with a feeler gauge and make a soft gasket to seal the flange to the firewall

pro70z28 · 10-25-2009, 07:38 PM

Engine side of the flange bored to size for the tubes.

Got everything mocked up. The flanges on the windshield will be added to the inlet side. I'll turn those once I get the V-band clamp. Should be here any day. The outlet side attaches to the carb bonnet with hose & clamp.

rallye bob · 10-26-2009, 04:52 AM

No "flex" joints?

pro70z28 · 10-26-2009, 02:49 PM

Quote:

Originally Posted by rallye bob

No "flex" joints?

Yes, they will be beyond these. This is to get the tube through the firewall only.

pro70z28 · 10-27-2009, 08:49 PM

Made a little more progress. I put the ol' foam mock up engine in it to make sure I get the angles right before going too much further. (Joint will go where the dark red tape is).

pro70z28 · 11-08-2009, 08:16 PM

I've been runnin' the lathe off & on the last few days & got the V-Band clamp flanges done.

Assembled and ready to TIG together

one more check to make sure everything fits like it should.

pro70z28 · 04-18-2010, 07:15 PM

Had a little time yesterday to work on the "Z". I straightened up a couple places on the firewall so I'd have a straight clean edge to start rebuilding. Then I made one of the two wells the intercooler tubes will pass through. I might use this one or I may try another approach. I'd like the mating surface to be a little smoother than this one. [shrinker sorta' wrinkled it a little]. This is my first attempt at any ''real'' metal shaping so there may be a few trial & error attempts on this deal.

pro70z28 · 05-09-2010, 07:41 PM

I changed up the design of the firewall some. The change affected the shape of the intercooler flange wells. I decided to stamp the parts, I guess mainly because I wanted to give stamping a try.
I cut dies out of 3/4" MDF board & stamped the sheet metal on the press.

then I rough trimmed the parts.

cleaned them up

Welded the front & back halves together

Once I had the tube flanges where I wanted them I welded them together.

pro70z28 · 05-09-2010, 07:44 PM

Sorry I got carried away on the project & by the time I remembered to take pictures I had the outlet tube firewall sheet metal done.
This is the firewall before...

and with the intercooler tubes part of the sheet metal in place.

The inlet side is just a simple pie plate deal that will be trimmed & welded into the firewall eventually.
The outlet side was a little more complicated. I didn't want to run the plumbing off to the side (the way it's usually done). I wanted the carb hat facing straight back. Also, the engine is set back about 4" from the stock location. So, the 4" inlet tube has about 3/8" clearance between the windshield and about 1" clearance for the distributor. It's all pretty close but it fits. . The "through the firewall sheet metal'' for the inlet tube ended up looking sorta like shoving the flange through a hefty hefty trash bag.

...and here's what it looks like from "the office".

10-23-2009, 10:12 PM	#1
pro70z28 Junior Member Join Date: Mar 2008 Posts: 73 Likes: 0 Liked 0 Times in 0 Posts	Firewall Project I'm ready to rebuild the firewall. I cut the flanges out today for the intercooler tubes to pass through the firewall. I'll turn them down on the lathe & weld them in place & shape the sheet metal around them.

10-25-2009, 07:36 PM	#2
pro70z28 Junior Member Join Date: Mar 2008 Posts: 73 Likes: 0 Liked 0 Times in 0 Posts	Re: Firewall Project Got the flanges turned this weekend. I put a groove around the edge of the flange for the firewall sheet metal. Once I install the o-ring and get in place I'll check the new gap with a feeler gauge and make a soft gasket to seal the flange to the firewall

10-25-2009, 07:38 PM	#3
pro70z28 Junior Member Join Date: Mar 2008 Posts: 73 Likes: 0 Liked 0 Times in 0 Posts	Re: Firewall Project Engine side of the flange bored to size for the tubes. Got everything mocked up. The flanges on the windshield will be added to the inlet side. I'll turn those once I get the V-band clamp. Should be here any day. The outlet side attaches to the carb bonnet with hose & clamp.

10-26-2009, 04:52 AM	#4
rallye bob Member Join Date: Sep 2006 Location: Genoa, Illinois Posts: 488 Likes: 8 Liked 6 Times in 4 Posts	Re: Firewall Project No "flex" joints?

10-27-2009, 08:49 PM	#6
pro70z28 Junior Member Join Date: Mar 2008 Posts: 73 Likes: 0 Liked 0 Times in 0 Posts	Re: Firewall Project Made a little more progress. I put the ol' foam mock up engine in it to make sure I get the angles right before going too much further. (Joint will go where the dark red tape is).

11-08-2009, 08:16 PM	#7
pro70z28 Junior Member Join Date: Mar 2008 Posts: 73 Likes: 0 Liked 0 Times in 0 Posts	Re: Firewall Project I've been runnin' the lathe off & on the last few days & got the V-Band clamp flanges done. Assembled and ready to TIG together one more check to make sure everything fits like it should.

04-18-2010, 07:15 PM	#8
pro70z28 Junior Member Join Date: Mar 2008 Posts: 73 Likes: 0 Liked 0 Times in 0 Posts	Re: Firewall Project Had a little time yesterday to work on the "Z". I straightened up a couple places on the firewall so I'd have a straight clean edge to start rebuilding. Then I made one of the two wells the intercooler tubes will pass through. I might use this one or I may try another approach. I'd like the mating surface to be a little smoother than this one. [shrinker sorta' wrinkled it a little]. This is my first attempt at any ''real'' metal shaping so there may be a few trial & error attempts on this deal.

05-09-2010, 07:41 PM	#9
pro70z28 Junior Member Join Date: Mar 2008 Posts: 73 Likes: 0 Liked 0 Times in 0 Posts	Re: Firewall Project I changed up the design of the firewall some. The change affected the shape of the intercooler flange wells. I decided to stamp the parts, I guess mainly because I wanted to give stamping a try. I cut dies out of 3/4" MDF board & stamped the sheet metal on the press. then I rough trimmed the parts. cleaned them up Welded the front & back halves together Once I had the tube flanges where I wanted them I welded them together.

05-09-2010, 07:44 PM	#10
pro70z28 Junior Member Join Date: Mar 2008 Posts: 73 Likes: 0 Liked 0 Times in 0 Posts	Re: Firewall Project Sorry I got carried away on the project & by the time I remembered to take pictures I had the outlet tube firewall sheet metal done. This is the firewall before... and with the intercooler tubes part of the sheet metal in place. The inlet side is just a simple pie plate deal that will be trimmed & welded into the firewall eventually. The outlet side was a little more complicated. I didn't want to run the plumbing off to the side (the way it's usually done). I wanted the carb hat facing straight back. Also, the engine is set back about 4" from the stock location. So, the 4" inlet tube has about 3/8" clearance between the windshield and about 1" clearance for the distributor. It's all pretty close but it fits. . The "through the firewall sheet metal'' for the inlet tube ended up looking sorta like shoving the flange through a hefty hefty trash bag. ...and here's what it looks like from "the office".