Firewall Patch Panel Question

Hey guys,

New to doing any sort of body work / patch panels. My rebuilt Dauntless is just about to come home from the machine shop and I need to do some work on the Firewall. The PO(s) put about 4 - 5 different holes in for the various heater cores that were used over its life. My plan is to cut out a square around these holes and replace with a new piece of sheet metal.

Two questions:

1.) what guage of sheet metal is the stock firewall?
2.) where is the best place to get/order patch panels?

Thanks for your help!

 

If I were you I would make square patches and stich weld them inside the firewall, that way you could finish them off with body filler if that is what you want. I replaced my firewall, with the one off the donor Jeep.

 

I did this very thing on my cj5.I used 18 ga.

Filled all holes . after body and paint. also filled holes in inner fender panels

 

WOW, very nice, Beautiful. you must have had that welder turned all the way down. I recommended overlay patches because I thought it would be easier for a inexperienced welder. You Jeep is "Garage Art", at it's best. I would like to see more of that Jeep Mike, thanks for sharing.

 

Thanks Rick, not a expert but I run .023 wire on pretty low setting for sheet metal. Good control at least for me.

 

Get Cold Rolled metal. Finishes better, but will be harder to bend.

 

I have a Miller 180 with .023 wire, my problem is at 72 I have to practice on scrap until I get settled down or warmed up enough to actually weld on my project. As an Ironworker we had to have a welding License to weld on projects, but stick welding on girders is a lot different than welding 16- 18 gage sheet metal.

 

This thread came up just in time for me because I had to do the same thing, cut out a section of the holed-up firewall and weld in a new panel. I'm a total beginner and this was my first attempt welding sheet metal.

The obvious problem in my '68 tub:


I made a cardboard template that would cover the majority of the holes:


I prepared to cut out the cancerous area:


I used a sawzall to make the cut, but it was hard to keep the blade going straight. Next time, I'm just going to use a cutting disc in a grinder.


I had to go buy a sheet of 16g steel. I cut out the patch panel with a cutting disc in a grinder:


Harbor Freight clamp things holding the panel in place:


Panel tacked in place:


Being a complete novice, I just kept going around and around with dots until all the dots connected. Sort of looks like Frankenstein, but now I should be able to install an Advance Adapters swinging pedal kit:


I guess this is all warm-up for replacing the floor pans.

 

Id like to see your swinging pedal install!

 

I forgot the most important part of the whole firewall replacement. ITLKSEZ talked me through the whole operation, like a pilot on the ground talking a passenger in a plane into successfully landing a 747.

 

nothing to be ashamed of there,grind,sand ,fill,paint. it looks like it didn't warp which is the most important thing.well next to being welded.

 

Man that is some great work!

 

I have found that a little Saber saw with a Lenox 24t Bi Metal blade does a wonderful job on stuff like this as long as you have clearance for the foot of the saw to rest against the metal you are cutting.

I even made two 4' log cuts in .090T 3x4 rectangular tubing to make a new bumper. Came out so straight a little draw filing and it was golden. Yes it took a while but it worked really well. So much less clean up time.

 

Hey, you have more skills than you give yourself credit for.