Firewall How-To

SoCalRT · 06-02-2008, 09:18 PM

So a couple of weeks ago I made a firewall out of aluminum and I think it came out pretty good and it was also pretty inexpensive to complete. I then did one for BigAl SE and also one for Catzcradle SXT so I could make some patterns. I thought I start making some up, but I just don't have the time so here is a walk through on how to make one yourself. Some of the tools needed are tin snips, drill, hole saws, assorted files and sanding blocks. On the first couple I did I used tin snips only and they don't leave the best edge and my hands were killing me, so I switched to a saber saw with a 32-36 TPI blade and it came out much smoother...

First you will need to make a pattern, but before that you need to remove the thing attached to the passenger side fender liner with the vacuum hoses. I just moved it back and attached it to the large bundle of wires. You will also need to remove the little panel seen below and the PCM mount 13mm bolts.

I started with construction paper that I pressed into the area after I guesstimated the shape and once I was happy with the fit I transferred it to poster board and fine tuned it by cutting and added paper where needed.

Once you are happy with the pattern, transfer it to the aluminum with a black Sharpie. Flip the pattern so you are putting it on the back of the material to reduce damage when you are cutting it out. On the curves I used a circle gauge and drilled out holes with a hole saw to get a good curve.

Once the layout it complete drill the holes and connect the dots. with the saw a was able to get much closer to the finished edge with little risk of damage. After a few trial fits and additional trimming, you want to leave about a #2 pencil width between the firewall and the engine so it won't rub with the engine running. we made Catzcradle a little close and he needed to do some additional trimming when he got home. Then sand it to prep for paint, punch or drill mounting holes and install. I did 5 mounting spots, one in the center and one one each side in the center of the curve and one on each end...

One thing I did my new one was add tabs to the end as the cross bar it mounts to has very solid braces at the ends, plus it cleans up the end as well. the end 13mm bolt secures the firewall...On the SXT cover we covered to large vacuum hose with braided stainless and used a 3/4" grommet for additional protection...

I bought a 3 x 5 sheet of heavy aluminum for $27.00 and it is enough for 4 or 5 firewalls a couple of bucks for paint ans screws and your good to go...

Go for it, you know you want one...