Weldless firewall repair (Updated)

Topics that are not specific to diesel or gasoline engines.

Moderators: Paul, puttputtinpup, How-to Authors

Post Reply
User avatar
arrowmntdiesel
Regular Member
Posts: 2766
Joined: Wed Apr 05, 2006 10:36 pm
Location: Medford, Oregon

Weldless firewall repair (Updated)

Post by arrowmntdiesel »

I have been working on a spare Pup that I have at home and one of the repairs on it is the "oh so common" broken out firewall where the clutch cable goes through. The original metal is very thin there and with so many other items in close proximity, I did not want to get the welder out for a temporary, messy repair,so...... here is a few pictures of what turned out to be a very solid repair that improved the feel of the clutch alot. The next set that I make I will change alittle to make installation better, but that is to be expected on the first try. I have templates made up so the next go around will not be so time consuming in the mock up. No special tools were needed other than the two hole saws for the two different size cable openings. Might work for other people if the need arrives for you!

Thanks for looking,

Mark
Attachments
Here is the truck I am working on at home. Some of you will remember this truck from better than a year ago.  It is finally getting some attention.
Here is the truck I am working on at home. Some of you will remember this truck from better than a year ago. It is finally getting some attention.
Just a "Teaser" of how rust free this truck is!  The cab bolt behind the seat.  Big smile!!!
Just a "Teaser" of how rust free this truck is! The cab bolt behind the seat. Big smile!!!
Here is what I started out with???? I don't know that I have ever seen one in such poor shape, at least as far as what is missing. Can't believe I was able to drive this truck up on the trailer.
Here is what I started out with???? I don't know that I have ever seen one in such poor shape, at least as far as what is missing. Can't believe I was able to drive this truck up on the trailer.
I believe this will be more typical of the firewall breaks out there. The grommet coming through the firewall is still there. This will most likely cause the cable hole on the interior plate to be the same size as the engine compartment plate.
I believe this will be more typical of the firewall breaks out there. The grommet coming through the firewall is still there. This will most likely cause the cable hole on the interior plate to be the same size as the engine compartment plate.
I was able to use this cab as my mule in the mock up. So easy access to both the inside and outside were helpful. This is an '86 cab and I used the plates on an '82. It still worked, but a small bit of filing was required in the final fit. Just a bit of difference.
I was able to use this cab as my mule in the mock up. So easy access to both the inside and outside were helpful. This is an '86 cab and I used the plates on an '82. It still worked, but a small bit of filing was required in the final fit. Just a bit of difference.
Both the interior and exterior plate ready to go on the truck. This is 1/4" aluminium plate. Strong enough and easy to work with. I cut it on a metal bandsaw and sanded the edges with a wet belt sander.
Both the interior and exterior plate ready to go on the truck. This is 1/4" aluminium plate. Strong enough and easy to work with. I cut it on a metal bandsaw and sanded the edges with a wet belt sander.
The engine compartment plate sits on top of the existing nuts that are welded to the firewall, therefore there is a space between the plate and the firewall, I uses some foam rubber material and a gasket with cutouts for the nuts and the cable. The two screws on top of the plate are adjustable to take any "rocking" motion out of the plate. These screw up tight against the firewall. The bottom two 8mm bolts are treaded to match the treads in the firewall. (this I will change, did't like that)
The engine compartment plate sits on top of the existing nuts that are welded to the firewall, therefore there is a space between the plate and the firewall, I uses some foam rubber material and a gasket with cutouts for the nuts and the cable. The two screws on top of the plate are adjustable to take any "rocking" motion out of the plate. These screw up tight against the firewall. The bottom two 8mm bolts are treaded to match the treads in the firewall. (this I will change, did't like that)
The interior plate with the pedal assembly attatched. The pedal height is adjustable to match the break pedal, so the added 1/4" is not an issue.
The interior plate with the pedal assembly attatched. The pedal height is adjustable to match the break pedal, so the added 1/4" is not an issue.
Here it is with the cable back in and working, No more squishy pedal.
Here it is with the cable back in and working, No more squishy pedal.
Last edited by arrowmntdiesel on Fri Jun 06, 2008 11:21 pm, edited 1 time in total.
AAS degree Diesel Technology 2014, 15 yrs Isuzu Pup diesels. Owner: Arrow-Mountain Diesel services & Arrow-Mnt Windows, Medford, OR. Love God! One Marriage-One Wife, 2 awesome young ladies as my kids. Happily Married for 30+ years. One Blessed Man!
User avatar
dunkel
Regular Member
Posts: 239
Joined: Wed Mar 05, 2008 7:36 pm
Location: Atlanta, GA

Re: Weldless firewall repair

Post by dunkel »

Looks good. The pics are great, too.
'88 Pickup 4wd Standard Cab 2.6 Gasser 2" suspension lift
Official member of Jeep Recovery Team
User avatar
pup daddy
Regular Member
Posts: 352
Joined: Fri Apr 22, 2005 10:12 am
Location: Lancaster, SC

Re: Weldless firewall repair

Post by pup daddy »

My turbo pup wants one. :(

Have you noticed on any of your trucks something that looks like a shock absorber hooked to the clutch pedal and the firewall? My turbo has it but not my 84 or 85. I unhooked it and couldn't tell any difference. What is it used for??

pup daddy
1985 Pup diesel 4x4 4spd SB (daily truck)
1986 Pup diesel 4x2 turbo LB (Waiting for some love)
1990 chevrolet 454SS pickup
1983 Mercedes 300sd
User avatar
puttputtinpup
Regular Member
Posts: 11152
Joined: Sat Oct 08, 2005 5:18 am
Location: Winston Salem, NC

Re: Weldless firewall repair

Post by puttputtinpup »

Mark, that is great work! Make up several sets. I'd be interested in buying a kit. So far, my 82's is still intact. I chuckled when I saw several guys checking out my firewall at the Pup meet to see if mine was broken. They assured me it was fine! :lol: but who know for how long, right?
Andy
User avatar
NeDieselLUV
Regular Member
Posts: 130
Joined: Tue Dec 04, 2007 12:57 pm
Location: Lincoln, Ne

Re: Weldless firewall repair

Post by NeDieselLUV »

I want your rust free red cab! Wow!!!

Great pics too!
1981 Chevrolet Luv 2wd - 121k - 2.2L Diesel - SOLD
1980 Chevrolet Luv 4wd - 120k - Black - RIP
1980 Chevrolet Luv 4wd - 140k - Red/Rust - Parted/Crushed
1999 Taurus SHO - 98k - 3.4L V8 32 Valve DOHC
1993 Taurus SHO - 165k - MTX
User avatar
arrowmntdiesel
Regular Member
Posts: 2766
Joined: Wed Apr 05, 2006 10:36 pm
Location: Medford, Oregon

Re: Weldless firewall repair

Post by arrowmntdiesel »

NeDieselLUV wrote:I want your rust free red cab! Wow!!!

Great pics too!


Believe Me, I was just as shocked when I pulled up the vinyl flooring and insulation. :D I have not seen one with the bolts still yellow with the original protective coating still intact. There was just abit of paint flaking along the sill where water had gotten in and sat, so I stripped that area and treated it with a rust netralizer and then painted it red again.

All of this work is being done in preparation for the truck to be sold. I have my 8th grade daughter's Washington DC trip in September of this year, and one or two of my trucks are going to need to be sold to pay for the trip for her and I. I am not quite ready to post it yet, but don't mind showing the progress here on the site. I will offer it here of course first. This is really turning out to be a great little truck. Still working on the interior right now.

Thanks!
Mark
Attachments
IMG_2178.jpg
IMG_2255.jpg
IMG_2256.jpg
IMG_2257.jpg
AAS degree Diesel Technology 2014, 15 yrs Isuzu Pup diesels. Owner: Arrow-Mountain Diesel services & Arrow-Mnt Windows, Medford, OR. Love God! One Marriage-One Wife, 2 awesome young ladies as my kids. Happily Married for 30+ years. One Blessed Man!
kravdraa
Regular Member
Posts: 1811
Joined: Mon Jan 29, 2007 11:23 am
Location: Burke, VA

Re: Weldless firewall repair

Post by kravdraa »

Mark, Excellent fire wall fix. Looks similar to one I did. I was able to keep the gromet hole (Used my Bridgeport Milling machine) by boring a percision plate around the hole. It was a light press fit and had lots of margain around it to bolt over the good metal.
:-)
Eric
81 Long bed PuP 2.2 Diesel
Using Bio-D
User avatar
arrowmntdiesel
Regular Member
Posts: 2766
Joined: Wed Apr 05, 2006 10:36 pm
Location: Medford, Oregon

Re: Weldless firewall repair

Post by arrowmntdiesel »

Thanks Eric.

I was amazed at just how bad the breakage was on the red truck. The grommet was totally missing! With the "Mule" truck available to mock it up, I was able to get dimensions for the plate to work on a truck that still had a good firewall or a truck that was as bad as the one I was working with. It sure did make for a nice tight clutch operation! :D

Mark
AAS degree Diesel Technology 2014, 15 yrs Isuzu Pup diesels. Owner: Arrow-Mountain Diesel services & Arrow-Mnt Windows, Medford, OR. Love God! One Marriage-One Wife, 2 awesome young ladies as my kids. Happily Married for 30+ years. One Blessed Man!
User avatar
arrowmntdiesel
Regular Member
Posts: 2766
Joined: Wed Apr 05, 2006 10:36 pm
Location: Medford, Oregon

Re: Weldless firewall repair (Updated) 6/06/08

Post by arrowmntdiesel »

Just went through another firewall repair and ended up changing the system a bit for what is an improved mount. This was out of nessecity due to the amount of damage to the firewall itself and what was missing. To date I have not seen a firewall this bad. :( :?: There was very little left to work with, so a 90 degree piece of 1/4" aluminum plate was selected for the repair this time.

I'll let the picture do the talking.

Mark
Attachments
Here is the damage I started out with. This is the "Poor Lil Ole Pup" project that I have been working on. I have not seen one ever this bad. This will take some work!!
Here is the damage I started out with. This is the "Poor Lil Ole Pup" project that I have been working on. I have not seen one ever this bad. This will take some work!!
This piece of aluminum was found at a local metal supply in the scrap bin. I paid $6.50 for it in weight. There is enough to do 3 plates. Aluminum is very easy to work with and it cut and drilled well.
This piece of aluminum was found at a local metal supply in the scrap bin. I paid $6.50 for it in weight. There is enough to do 3 plates. Aluminum is very easy to work with and it cut and drilled well.
These are the same templates I used on the first set with just a few changes. Here I am just setting my length.
These are the same templates I used on the first set with just a few changes. Here I am just setting my length.
This is looking at the damaged area from the engine side with the cab side plate in place. This firewall is needing that extra strength of the angle pieces
This is looking at the damaged area from the engine side with the cab side plate in place. This firewall is needing that extra strength of the angle pieces
The cab side plate with the return shown to where it will be bolted to an existing body plate.
The cab side plate with the return shown to where it will be bolted to an existing body plate.
Teresa is holding the engine side plate showing the short return of the angle plate. This was trimmed on the same bandsaw as used to cut the length.
Teresa is holding the engine side plate showing the short return of the angle plate. This was trimmed on the same bandsaw as used to cut the length.
This is the biggest hurtle in this repair to get over. There is only 4" of space to drill those holes and a 90 degree head drill is the only way to get in there. I did not have one and did not have the $ to buy one. The tool store rented me this for $15. That kept me going and gives me a new tool to save up for.
This is the biggest hurtle in this repair to get over. There is only 4" of space to drill those holes and a 90 degree head drill is the only way to get in there. I did not have one and did not have the $ to buy one. The tool store rented me this for $15. That kept me going and gives me a new tool to save up for.
This is a veiw from up under the dash after the new plate was installed. Again the angle aluminum offered much better rigidity that this truck need badly. The pedal height was adjusted after the cable adjustment and both pedals sit at the same height.
This is a veiw from up under the dash after the new plate was installed. Again the angle aluminum offered much better rigidity that this truck need badly. The pedal height was adjusted after the cable adjustment and both pedals sit at the same height.
Here is the engine side with the small 90 degree return on the master cylinder side. This accomplished two things. One, for this truck it bridged a span were some metal was missing and Two, it stablalized the plate that is sitting on top of the existing nuts that were welded onto the firewall. Only three on this truck due to one missing completely.
Here is the engine side with the small 90 degree return on the master cylinder side. This accomplished two things. One, for this truck it bridged a span were some metal was missing and Two, it stablalized the plate that is sitting on top of the existing nuts that were welded onto the firewall. Only three on this truck due to one missing completely.
AAS degree Diesel Technology 2014, 15 yrs Isuzu Pup diesels. Owner: Arrow-Mountain Diesel services & Arrow-Mnt Windows, Medford, OR. Love God! One Marriage-One Wife, 2 awesome young ladies as my kids. Happily Married for 30+ years. One Blessed Man!
User avatar
puttputtinpup
Regular Member
Posts: 11152
Joined: Sat Oct 08, 2005 5:18 am
Location: Winston Salem, NC

Re: Weldless firewall repair (Updated)

Post by puttputtinpup »

Again, Mark. Nice work!! Would it have been possible to place the inner plate up to the firewall, scribe the holes to be drilled, remove it, then drill them on a press (a little larger to allow for error? ) or get a piece of poster-board and use as a template. Maybe I'm not seeing the whole picture. :idea: Oh, I get it! Then you wouldn't have a case for getting a new toy... :oops: tool! :lol:
But really, how to do do it????......manage to get Teresa to help you :? Marsha shakes her head and says "Teresa's weak. She's losing ground"
Andy
User avatar
arrowmntdiesel
Regular Member
Posts: 2766
Joined: Wed Apr 05, 2006 10:36 pm
Location: Medford, Oregon

Re: Weldless firewall repair (Updated)

Post by arrowmntdiesel »

Andy,

Yeh, the plate was predrilled on the drill press. It is the body rib up undernieth the dash that needs to be drilled in place. I got this all together yesterday and my original clutch issue is gone! :D :D I have a very solid clutch feel now. It's any wonder I was able to get it in and out of gear at all as bad as this was.

In refference to Teresa helping,....Well.... :?: :) Maybe I can get some back-up here from Dave (Dccunning) because Donna seems to get it also! The benifits of a mutual relationship in all areas of a marriage have great rewards at the end of the sale!! :D Talk to you later
Andy, I've got to get up and go do the dishes!! :D :D

Mark
AAS degree Diesel Technology 2014, 15 yrs Isuzu Pup diesels. Owner: Arrow-Mountain Diesel services & Arrow-Mnt Windows, Medford, OR. Love God! One Marriage-One Wife, 2 awesome young ladies as my kids. Happily Married for 30+ years. One Blessed Man!
User avatar
John Boyd
Regular Member
Posts: 40
Joined: Sun Nov 16, 2008 5:31 pm
Location: Plant City FL &

Re: Weldless firewall repair (Updated)

Post by John Boyd »

Add another clutch cable repair for my 86 PUP, performed in the carport some years ago from scrap aluminum.
Pictures attached for cable installation.
Also picture of disabled air pump.
Attachments
The air pump is no longer is use.
The air pump is no longer is use.
Imported Photos 00370.JPG (75.6 KiB) Viewed 13030 times
Imported Photos 00372.JPG
Imported Photos 00371.JPG
Imported Photos 00371.JPG (88.79 KiB) Viewed 13028 times
John Boyd
rpus
Regular Member
Posts: 13
Joined: Wed Aug 08, 2007 5:29 pm

Re: Weldless firewall repair (Updated)

Post by rpus »

Ok, call me crazy or cheep, wife would say nuts for still having the truck, but i took Mark's basic pattern/idea, but uses a 1/4 inch plastic cutting board to fix my 86. Five months into a cold Nebraska winter and not one issue with the fix. Strong, sturdy, and simple as heck to work with, the cable grommet hole can be drilled with a $5.00 hole saw, cut with a jig saw, and you can cut both pieces from a $7.00 cutting board from Walmart. And the peddle feel is great. If and when i ever get my my camera working, i will add them to the post.
User avatar
John Boyd
Regular Member
Posts: 40
Joined: Sun Nov 16, 2008 5:31 pm
Location: Plant City FL &

Re: Weldless firewall repair (Updated)

Post by John Boyd »

Not free, but cheap enough to fix with a cutting board.
When my trans kept popping out of 5th, the garage wanted $200. just to look at it. I bought a bungy cord for 38 cents and attached it to the dash. That was 20 years ago. Works fine.
John Boyd
Pupfriend
Regular Member
Posts: 448
Joined: Fri Dec 07, 2007 6:31 pm
Location: Rainbow City, Alabama

Re: Weldless firewall repair (Updated)

Post by Pupfriend »

John Boyd wrote:Not free, but cheap enough to fix with a cutting board.
When my trans kept popping out of 5th, the garage wanted $200. just to look at it. I bought a bungy cord for 38 cents and attached it to the dash. That was 20 years ago. Works fine.


LOL,
I thought I was the only one to do that! I told some of the guys at the airport, that my 'ole Nissan diesel King Cab had a "stick shaker" just like the jumbo jets.....I kept the bungee looped around the heater somewhere under the dash. Since it was about a 4am 37 mile morning commute I didn't have to shift much and it worked well.

Eddie
1986 SWB 5spd diesel P'up (sold)
1981 2dr Auto LS I-Mark diesel (need windshield);
198? 4dr Auto gas I-Mark (parts);
91(sold) and 94 Isuzu 2.3 p/u(daily driver);
'87 1.9L LS Pup;
A few Nissan SD22 diesel engine parts,
Post Reply