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Body Repairs: Firewall Removal

With the body cross-braced and mounted on the new chassis, replacing the firewall was the first step.

Removing the firewall requires drilling out about 80 spot welds. The most difficult ones to get at are where the firewall attaches to the toe boards. Unless you absolutely have to save the old firewall, I suggest cutting out the center of it with a torch or plasma cutter. You still have to drill out all the spot welds, but removal will be easier with less chance of damaging the cowl sheet metal.


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Even after drilling out the spot welds, this firewall was rust-welded to the cowl and getting it out in one piece was difficult.


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Installation of the firewall had to wait until I could repair the lower cowl “boxes”, replace the lower cowl sheet metal and replace the rocker panels.

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