Well I've been working on this car for 2 days now and have made some good progress. My friend had drilled out all of the spot welds and pulled some pieces from behind the dash, so we could cut out the firewall without cutting anything else. We would have to plug weld everything back in later.
I wanted to leave 2" all the way around the firewall and then, but the new firewall up against it. Some areas still need some extra attention.
Here is the first rough cut of the existing firewall.
Next I cut the right hand drive firewall out of the donor car. After some trimming I was able to get a rough fit.
Here are the problem areas I was speaking of. Since the upper portion of the car could not be touched due to the vin not being cut the rain gutter is flipped and caused a few issues for us.
Rain gutter dips in on this side
We had to cut into the rain gutter on the "new driver's side" to get the firewall to sit flush.
My first order of business today was to get the rain gutter patched up, so that he wouldn't have water leaking into the car.
I formed a piece using my beverly shear a hammer and a vice.
Rain gutter patched in. Not pretty, but at least it isn't a hole. We will run some seam sealer around it to be sure it doesn't leak.
I used the beverly shear again the cut and form a piece of sheet metal to fill in the large gap on the " new passenger side" of the car. I used sheet metal screws to pull the firewall tight to the old piece of firewall the remained in place and then started welding it up.
Started tacking the whole firewall in place.
Sealing it up.
Once I welded it all the way around, I erased the weld seam on the patch that was made.
We started plug welding the pieces back inside the car and filling all of the holes.
We have a few more holes to plug weld and then we will move to the inside of the car and put the rest of the right hand drive parts in place.
