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17 June 2011

Up Against The Wall

The firewall took much longer than anticipated.  I'll keep the story short...the upper cowl shown in the earlier post was so cracked and damaged in areas that would have been practically impossible to repair.  I decided to get a new one.  After a long search, I found one at Dr. Rebuild (a Corvette restoration parts vendor), and fortunately for me, the warehouse is five miles from my house.


The firewall finally repaired and looking pretty.

The metal plate is where the upper bolts of the brake/clutch pedal assembly attach. It had to be removed from the old upper cowl and riveted to the new one.

The reenforcement plate for the windshiled wiper motor.  It, too, had to be removed from the old and rivetted to the new. Not pictured here is the pass side hood latch attaching plate that also had to be removed and rivetted.  All metal hardware was sandblasted and coated with POR-15.

All ready for installation.

This was my first attempt at using fiberglass/SMC adhesive. So I took DUB's advice and ran rehearsals, determining where clamps and weights had to go, and how long it would take.  Then before the installation, I did a trial mix of  the adhesive and hardener ratio to determine the working time I would have in the temp/humidity conditions and mixed it so that it would not rock up before my working time to lay the adhesive and install the cowling.  Taped to the winshield is a pic of the clamp/weight configurqation to use during the final install.  It all went like a charm.

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