{"id":2055,"date":"2018-04-05T18:16:40","date_gmt":"2018-04-05T18:16:40","guid":{"rendered":"https:\/\/eoffer.us\/?p=2055"},"modified":"2024-03-11T11:33:06","modified_gmt":"2024-03-11T11:33:06","slug":"project-why-wait-installing-ls-fabrication-firewall-fillers","status":"publish","type":"post","link":"https:\/\/eoffer.us\/index.php\/2018\/04\/05\/project-why-wait-installing-ls-fabrication-firewall-fillers\/","title":{"rendered":"Project Why Wait: Installing LS Fabrication Firewall Fillers"},"content":{"rendered":"
After unboxing the Langes Shop (now LS Fabrication) firewall fillers<\/a> in the last Project Why Wait<\/a> update I had a bit of a \u201cwhat have I got myself into\u201d moment when reality set in. I\u2019d never welded sheet metal before and I was about to cut out my firewall.<\/p>\n Reading about it<\/a>, and watching others do it, is one thing but picking up the torch and getting it done? Another entirely.<\/p>\n However Chris Lange (the Lange in Lange\u2019s Shop<\/a>) reassured me that the installation is fairly straight forward. Even for the inexperienced weekend warrior typing this post.<\/p>\n So, instructions in one hand and a grinder in the other, it was time to make some sparks.<\/p>\n <\/a><\/p>\n First things first, I had to clear the cab of anything particularly flammable. Cleaning out a 67-year-old truck,\u00a0that\u2019s spent the last few years outside, is in no way an enjoyable task.<\/p>\n Animal feces, cigarette butts, tools, old clothes\u2026 you\u2019d be surprised just how much crap can hide in a truck that looked<\/em> empty. I didn\u2019t take any pics of this process as it was head down and plow through to better things ahead.<\/p>\n <\/a>With everything cleared out, stripping what remained on the firewall off was next. Then I traced the firewall fillers with a sharpie before masking it out with tape.<\/p>\n With a fire extinguisher close at hand, I used an angle grinder fit with a thin cutting wheel to do the dirty work. The instructions state to leave about a 1\/2\u2033 over lap to make fit up a little easier so that\u2019s precisely what I did.<\/p>\n <\/a><\/a><\/p>\n I have to give a shout out to LS Fabrication for including two very crucial things in the instructions.<\/p>\n The first, was a photo of the firewall support you see above. I could have easily zipped those right off had the instructions overlooked mentioning them. Second, including what size drill bit to use for removing spot welds very<\/em> helpful.<\/p>\n At the time I didn\u2019t have a spot weld cutter so knowing what size to use, without several trips to the toolbox, really helped keep the pace up in the garage.<\/p>\n <\/a><\/p>\n Since I\u2019ve received my fillers, LS Fabrication has shipped several around the world. With so many builders using them each installer does things a bit differently. Some people have omitted cutting out the factory firewall entirely.<\/p>\n After briefly considering this approach, the fear of moisture accumulating between the factory firewall and the new panel scared me away.<\/p>\n <\/a><\/a><\/p>\n During fitment checks, and before tacking, I used some Gorilla tape to hold the fillers in place.<\/p>\n It\u2019s a bit crude, but, my small welding magnets were not quite up to the task.<\/p>\n <\/a><\/p>\n Once I was happy with fitment I tacked the panels in and checked everything again.<\/p>\n I actually ended up later removing the passenger side filler to cut out more material and fit it a bit better which you may notice in some of the photos below.<\/p>\n <\/a><\/p>\n At this point I could have welded the fillers in to create a lap weld. But after talking to a few friends (big thanks to Jeff Wybrow, Dennis Thorne and Pat Cheately) they all suggested running a cutting disc around the outside of the panel.<\/p>\n This would create a gap so I could butt weld the panels together versus lap welding them. Lap welding opens up an opportunity for moisture to accumulate and moisture leads to rust. That said butt welding is a somewhat more challenging because it is easier to burn through.<\/p>\n My machine set up for this job was a Lincoln MIG Pack 10, 110amp, welder and .030 wire.\u00a0Machine settings were pretty close to what was prescribed on the inside cover, save for minor wire speed adjustments as I went.<\/p>\n <\/a><\/p>\n <\/a>On the driver\u2019s side, after I cut all the way around, I ended up performing about a half-inch weld at a time. Alternating in a star pattern across the panel.<\/p>\n This method worked pretty well but it wasn\u2019t the typical method I read in similar how to articles.<\/p>\n <\/a><\/a><\/p>\n So, for the passenger side I did the tack, tack again, then tack between those tacks, method. I did that until there were no holes left in my line of tacks.<\/p>\n Using my air blower throughout helped minimize warping of the metal.<\/p>\n <\/a><\/p>\n <\/a>To be entirely honest both methods took about the same amount of time and looked reasonably similar after grinding.<\/p>\n Admittedly I think the heat affected the passenger panel a bit more (not to a noticeable degree once I finish it out) so my suggestion here would be use whichever method you feel most comfortable with.<\/p>\n Because I am learning, I tried both.<\/p>\n <\/a><\/p>\n Following the initial passes were steps I was familiar with; weld, grind, weld repeat.<\/p>\n The tools you see below got a lot of use this month, along with a set of safety goggles and a dust mask.<\/p>\n <\/a><\/a>After making a lot of noise and plenty of sparks I was able to get the firewall fairly blended in.<\/p>\n <\/a><\/a><\/p>\n Once I finish replacing the front of my floors (to be covered in another update) I\u2019ll put a little more metal work in before I break out the various body fillers.<\/p>\n I will also show you how I plan to tackle the inside of the firewall to make sure this job holds up to the tests of time.<\/p>\n <\/a><\/a><\/p>\n To get a head start on the bodywork I dug out some paint stripper and stripped everything off the firewall in the areas I will be working over.<\/p>\n Eventually the entire firewall will be completely stripped before it goes to Miltowne Collision<\/a>.\u00a0Any guesses on the color I\u2019m having the engine bay sprayed?<\/p>\n <\/a><\/a><\/p>\n At first glance the job might look daunting but it\u2019s really not too bad provided you have a welder and a slight bit of experience with it.<\/p>\n The visual change, even incomplete, is remarkable.<\/p>\n