Firewall Project
 

I'm ready to rebuild the firewall. I cut the flanges out today for the intercooler tubes to pass through the firewall. I'll turn them down on the lathe & weld them in place & shape the sheet metal around them.

http://img.photobucket.com/albums/v2...ewallstart.jpg

http://img.photobucket.com/albums/v2...llFlanges1.jpg

http://img.photobucket.com/albums/v2...llFlanges2.jpg

Re: Firewall Project
 

Got the flanges turned this weekend.

http://img25.imageshack.us/img25/8913/flangebore.jpg http://img25.imageshack.us/img25/fla...jpg/1/w850.png

I put a groove around the edge of the flange for the firewall sheet metal. Once I install the o-ring and get in place I'll check the new gap with a feeler gauge and make a soft gasket to seal the flange to the firewall

http://img196.imageshack.us/img196/8...flangeclea.jpg http://img196.imageshack.us/img196/f...jpg/1/w850.png

Re: Firewall Project
 

Engine side of the flange bored to size for the tubes.

http://img36.imageshack.us/img36/7459/flangetubefit.jpg http://img36.imageshack.us/img36/fla...jpg/1/w850.png

Got everything mocked up. The flanges on the windshield will be added to the inlet side. I'll turn those once I get the V-band clamp. Should be here any day. The outlet side attaches to the carb bonnet with hose & clamp.

http://img194.imageshack.us/img194/4...esmockedup.jpg http://img194.imageshack.us/img194/f...jpg/1/w850.png

Re: Firewall Project
 

No "flex" joints?

Re: Firewall Project
 

Yes, they will be beyond these. This is to get the tube through the firewall only.

Re: Firewall Project
 

Made a little more progress. I put the ol' foam mock up engine in it to make sure I get the angles right before going too much further. (Joint will go where the dark red tape is).

http://img23.imageshack.us/img23/236...ckup102709.jpg

Re: Firewall Project
 

http://img130.imageshack.us/img130/1...dassembly1.jpg

I've been runnin' the lathe off & on the last few days & got the V-Band clamp flanges done.

http://img33.imageshack.us/img33/720...dassembly2.jpg

Assembled and ready to TIG together

http://img440.imageshack.us/img440/2...dassembly3.jpg

one more check to make sure everything fits like it should.

Re: Firewall Project
 

Had a little time yesterday to work on the "Z". I straightened up a couple places on the firewall so I'd have a straight clean edge to start rebuilding. Then I made one of the two wells the intercooler tubes will pass through. I might use this one or I may try another approach. I'd like the mating surface to be a little smoother than this one. [shrinker sorta' wrinkled it a little]. This is my first attempt at any ''real'' metal shaping so there may be a few trial & error attempts on this deal.


http://img.photobucket.com/albums/v2...rtubewell1.jpg

http://img.photobucket.com/albums/v2...rtubewell2.jpg

Re: Firewall Project
 

I changed up the design of the firewall some. The change affected the shape of the intercooler flange wells. I decided to stamp the parts, I guess mainly because I wanted to give stamping a try.
I cut dies out of 3/4" MDF board & stamped the sheet metal on the press.

http://img.photobucket.com/albums/v2...ubewelldie.jpg

then I rough trimmed the parts.

http://img.photobucket.com/albums/v2...roughparts.jpg

cleaned them up

http://img.photobucket.com/albums/v2...artstrimed.jpg

Welded the front & back halves together

http://img.photobucket.com/albums/v2...cktubewell.jpg

Once I had the tube flanges where I wanted them I welded them together.

http://img.photobucket.com/albums/v2...8/WeldTube.jpg

Re: Firewall Project
 

Sorry I got carried away on the project & by the time I remembered to take pictures I had the outlet tube firewall sheet metal done.
This is the firewall before...

http://img.photobucket.com/albums/v2...Up10-27-09.jpg

and with the intercooler tubes part of the sheet metal in place.

http://img.photobucket.com/albums/v2...talinplace.jpg

http://img.photobucket.com/albums/v2...sheetmetal.jpg

The inlet side is just a simple pie plate deal that will be trimmed & welded into the firewall eventually.
The outlet side was a little more complicated. I didn't want to run the plumbing off to the side (the way it's usually done). I wanted the carb hat facing straight back. Also, the engine is set back about 4" from the stock location. So, the 4" inlet tube has about 3/8" clearance between the windshield and about 1" clearance for the distributor. It's all pretty close but it fits. . The "through the firewall sheet metal'' for the inlet tube ended up looking sorta like shoving the flange through a hefty hefty trash bag. :D

...and here's what it looks like from "the office".

http://img.photobucket.com/albums/v2...indoshield.jpg

Re: Firewall Project
 

If youre building a stocker Im seriously depressed, VERY VERY Nice work though......and Ill be resigning my overthing do it to the max overkill hat to you ........very very nice work.

But where did I miss what youre building ? Very very nice work especially the sheet work......

Re: Firewall Project
 

drooze, it's a pro street. I'll probably just bracket race it, at least at first.

It's a 70 Z-28 RS

http://img.photobucket.com/albums/v2...OPPANORAMA.jpg

http://img.photobucket.com/albums/v2...aroStands1.jpg

http://img.photobucket.com/albums/v2...aroStands2.jpg

Re: Firewall Project
 

Forgot I took some shots of the process when I stamped the shallower inlet side.

I cut the 3/4" MDF out on the CNC. I gave one side 1/8" clearance for the metal and the other side the circle press fit into the MDF.

http://img.photobucket.com/albums/v2...28/MDFdies.jpg

http://img.photobucket.com/albums/v2...edtogether.jpg

This made the die the right depth (I needed it to be stamped 1/2" deep for the right offset). It also made it easy to register the die halves.

http://img.photobucket.com/albums/v2...DiePressed.jpg

Once out of the press all I had to do was hammer the tucks and it's ready to trim to the firewall. The firewall that doesn't exist yet.

Re: Firewall Project
 

Got a little more done on the firewall this weekend between honey -do projects.

I made a hammer form out of a 2x4 on the band saw to match the contour of the firewall and beat some metal into submission. Still needs a little hammering but it's close enough for a test fit.

http://img.photobucket.com/albums/v2...ammerForm1.jpg


http://img.photobucket.com/albums/v2...sengerside.jpg

I decided to do recessed panels on the sides & I think I'll do raised panels on the front, but I've changes my mind so many times already, who knows.

http://img.photobucket.com/albums/v2...lSidePanel.jpg

http://img.photobucket.com/albums/v2...neltestFit.jpg

This part of the firewall will get welded to the body. The rest will get welded to the chassis and the 2 will be bolted or riveted together (blind seam) from the inside

http://img.photobucket.com/albums/v2...fit5-31-10.jpg

I think I spent more time in the lawn chair thinkin' about this than actually working on it. I kept changing the plans until I had a headache & finally decided to just do something. If it doesn't work I'll start over. I want to be able to take the body off, so that's why it's going to be a 2 pc. deal. Sort of the same reason I spent all that time on the billet aluminum hinges rather than just welding them to the chassis. Keeping the "A" pillars I'll still be able to use stock door weatherstripping and boxing in the firewall under the windshield I'll be able to keep the stock windshield wipers, got to keep it street legal right?

Re: Firewall Project
 

Got a little more done on the firewall this weekend, Welded a few of the small pieces to some of the medium sized pieces.

http://img.photobucket.com/albums/v2...all6-6-101.jpg

http://img.photobucket.com/albums/v2...all6-6-102.jpg

Re: Firewall Project
 

Nice work, wish I had that skill and patience.

Re: Firewall Project
 

You're a talented craftsman. Best wishes w/this car. WJ

Re: Firewall Project
 

Thanks 72 & WJ

Re: Firewall Project
 

Yes very nice work!

Re: Firewall Project
 

Thanks rayfin. Made another piece for the inlet side of the intercooler tonight.

http://img.photobucket.com/albums/v2...inletwell1.jpg

http://img.photobucket.com/albums/v2...inletwell2.jpg

http://img.photobucket.com/albums/v2...inletwell3.jpg

http://img.photobucket.com/albums/v2...inletwell4.jpg

Re: Firewall Project
 

Got the inlet side roughed in today.

http://img.photobucket.com/albums/v2...demockedup.jpg

And got a panel installed.

http://img.photobucket.com/albums/v2...idepattern.jpg

http://img.photobucket.com/albums/v2...debeadroll.jpg

http://img.photobucket.com/albums/v2...ewallready.jpg

I roughed up the back of the panel & the chassis tubes with 80 grit on the angle grinder, then glued it in with fusion body panel adhesive.

http://img.photobucket.com/albums/v2...linstalled.jpg

Re: Firewall Project
 

Added a couple more pieces to the puzzle this afternoon.

http://img.photobucket.com/albums/v2...assSideFW2.jpg

http://img.photobucket.com/albums/v2...assSideFW1.jpg

Re: Firewall Project
 

Wow, that is some nice work!!


You obviously have some things that I definitely lack; skill and patience..

Keep going. This is going to be an swesome car, and hand crafted beauty.

David
The New Hemi Guiy

Re: Firewall Project
 

that's some pretty nice looking stuff there......you need to take your pictures and start a thread on yellowbullet (in whatever power-adder you're using). The guys over there are a little rough around the edges, but there's a whole 'lotta knowledge to share and they'd also appreciate your handi-work.

Re: Firewall Project
 

Thanks Jim & Dave

Re: Firewall Project
 

Everybody (but me) had to work this weekend, we celebrated Father's day Thursday, so I had the weekend to work on the firewall. Got a fair amount done.

Since this WILL be a street legal car, I found a new spot to display the trim code tag.

http://img.photobucket.com/albums/v2.../pressdies.jpg

http://img.photobucket.com/albums/v2...etagStamp1.jpg

http://img.photobucket.com/albums/v2...iptmock-up.jpg

I stuffed it between the strut tube & the inlet side of the intercooler.
Also made paper patterns for a couple more pieces of the puzzle.

Re: Firewall Project
 

I decided to stamp a "Camaro: logo in the driver's side panel

http://img.photobucket.com/albums/v2...arologoCNC.jpg

http://img.photobucket.com/albums/v2...ologoparts.jpg

http://img.photobucket.com/albums/v2...oLogopress.jpg

http://img.photobucket.com/albums/v2...ogostamped.jpg

The press and bead rolling oil canned the panel a little but I think it will straighten out when I put the 7/8" tabs on the top & bottom with the brake.

It came out fairly clean, even the little piece in the top of the "o" stamped. That part was about 1/2 the size of a pencil eraser. When I paint the firewall I'll paint the logo over this, the stamping will give it a little extra "pop".

Re: Firewall Project
 

The more I looked at the Camaro panel the more things I found I didn't like. The deal breaker was when the bead rolled lines didn't match up to panel next to it. So, tonight I knocked out another one. It didn't take long since I had the stamp & measurements from the first "prototype". [ prototype = politically correct term to describe "junk part"]. I had to lay the panels in place to see how it was going to look. There's a lot of massaging to be do to get everything to fit, but it is getting closer.

http://img.photobucket.com/albums/v2...sroughedin.jpg

Re: Firewall Project
 

Sorry, haven't been around for awhile. The "Z" project has pretty much sat since last summer, but I got some time the last few days to get the firewall welded & in primer.

http://img.photobucket.com/albums/v2...all5-28-11.jpg

http://img.photobucket.com/albums/v2...med5-30-11.jpg

Got the front end set in place. Next project is to fit it to the car, fabricate hinges, tree & latch system.

http://img.photobucket.com/albums/v2...ace5-30-11.jpg

http://img.photobucket.com/albums/v2...d2-5-30-11.jpg

Re: Firewall Project
 

http://img.photobucket.com/albums/v2...end6-11-11.jpg

I started on the hinges but then decided I better get the front end straight first or the hinges would be wrong. (The front end is a mess) The nose didn't even come close to fitting, so I trimmed the opening & made cuts where I had to, to get it to match up

http://img.photobucket.com/albums/v2...ungtrimmed.jpg

I used some scrap aluminum from an old sign to get the nose in the right place.

http://img.photobucket.com/albums/v2...escrewedon.jpg

Glassed the blank spaces between the gussets. After it sets up I'll unscrew the gussets & finish the fiberglass, a job I'm just itching to get done. lol

http://img.photobucket.com/albums/v2...lassingin1.jpg

Re: Firewall Project
 

Pro,,,,I'm glad your project is still moving ahead, and its coming along well. I was glad to catch up with this older thread, and I'l admit a little saddened to see that Drooze chimed in on here, and his father Dave,, just a few weeks before Drooze's untimely accidental death last summer that truly shocked the Classracer.com community. His interest in your Camaro is proof of the varied ideas and angles he ran by all of us in the short time he was with us here. I'm glad his Drag Pak Challenger has proven to be a top notch race car, with Dave and crew continuing on,,and I hope your Camaro will do as well, whether on the street or on the strip. Good luck with your ride, its looking great.
Danny Durham

Re: Firewall Project
 

Thanks Danny. Very sorry to hear about Drooze.

Re: Firewall Project
 

The kids are on vacation so we are celebrating Father's Day Friday. I spent the last few days working on hinge designs. Each one had a little problem here or there but they all helped me come up with the final design. To get the front end to work like I hope it will, the front end has to come forward first 3.75'', then raise 2". Then flip up. I want it to be removable also. I came up with a bunch of ideas, some of the more promising ones I cut prototypes out of 1/4" PVC cut offs. First obstacle was getting the geometry right. After that was just making sure there was enough material in the right places & keeping it small enough to fit where it had to fit.

http://img.photobucket.com/albums/v2...prototypes.jpg

The last design came pretty close to fitting alongside the 3''x2'' main rails but still but I still wondered if I'd be kicking myself down the road when it came time to mount the radiator, pro charger & all the other stuff that needs to go in the front. Then I got the bright idea of building the linkage inside the frame rail. After a few more prototypes I think I have it, (works on the bench anyway) lol

So, today I cut out the CNC parts.
http://img.photobucket.com/albums/v2...gepartsCNC.jpg

Got a few parts to make on the lathe yet & some massaging to do on the frame rails to make everything fit. I guess if it doesn't work I'll just have to go back to the drawing board. Only 1 way to find out..................... Stay tuned.


http://img.photobucket.com/albums/v2...sofftheCNC.jpg

Re: Firewall Project
 

They fit on the outside of the rails. Now to get them to fit "inside".

http://img.photobucket.com/albums/v2...8/100_2124.jpg

Re: Firewall Project
 

Ya know.... one of these days, you're going to finish that car. Then, what will we have to ogle over ?

Nice work man !!

Re: Firewall Project
 

Thanks Kenny. I just keep pluggin' away ....when I can.
Had to work most of the day today, but I found enough time to assemble the hinges & buff them a little.

http://img.photobucket.com/albums/v2...sassembled.jpg

Re: Firewall Project
 

Got a little more done on the hinges. Made a jig to cut the frame horns off. Boxed in the rail to keep junk from getting down inside the frame. Welded them in along with some fish plates to weld the horns back on.

http://img.photobucket.com/albums/v2...horncutjig.jpg
http://img.photobucket.com/albums/v2.../frameplug.jpg
http://img.photobucket.com/albums/v2...iedtherail.jpg

I had a little ooops. I spun some bushing bungs on the lathe, welded them in & when I tested it the hinge came out of the rail. The pins were supposed to keep the hinge in the rail but there was just enough clearance for it to slip by.
http://img.photobucket.com/albums/v2...aceswelded.jpg

So I made up these little clips to grab the pin a little better. Ended up making clips for both pins. That meant the linkage would no longer fit inside the rail, so I made some c-channel out of square tubing for the bottom. Holes are for junk & water drainage. I'll have to add one on the top too. At least the hinge locks in place solid now, in both open & closed positions.

http://img.photobucket.com/albums/v2.../Hingeclip.jpg

Got a few more parts to make & they will be ready to weld back on. The 3/4'' pins are for alignment during welding, eventually they will be replaced with 3/4" nylon bushing stock & a 1/2" steel pin. Got some black corian® cut-offs from a counter top place. Cutting that on the CNC to fill in the gaps between the rails & the hinges, so there won't be any metal to metal contact. Nylon & corian® should allow the hinges to slide smooth.
http://img.photobucket.com/albums/v2...nsmockedup.jpg

I hope this deal goes a little better from here on out. Hate those glitches.

Re: Firewall Project
 

It's been awhile but I got some shop time in yesterday. Made shims for the front end hinges.

http://youtu.be/i91t1JwOGmU