Today I fabricated the firewall reinforcement. Since the clutch master cylinder is to be mounted to the firewall, I wanted to reinforce the area where it would mount. I decided to pick up the point where the brake master cylinder mounts. Once everything is finalized, I will go back and plug weld the firewall to this support. The reinforcement is going to be fabricated from 10-gauge steel.
Started with a poster board template
There will be an offset in the reinforcement to fit the firewall around the brake master cylinder.
Tracing the template onto the metal
Test fit of the first piece
Cutting out second piece
Forming the piece that will go in the brake master cylinder recess
You don't need any fancy bending tools. A vice, wood block and a hammer work just fine.
Tacking the pieces together
Finished welding it on the bench
Here you can see where the clutch master cylinder will mount.
Fabricated an angled spacer from delrin to allow for the angle of the firewall and mount the master.
I plan on trimming the spacer to the same shape as the base of the master cylinder. All the unused holes in the firewall will be welded up when I break everything down.
Brake booster / master cylinder / clutch master cylinder installed.
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