Now it is time for a couple more mods to the firewall and to close up a bunch of unused holes and openings. I started with the area around the brake booster/master cylinder opening. In it's previous life the owner had "adapted" a non-Nova booster to the firewall which apparently required multiple holes and an enlarged opening. I cut out the surrounding area and welded in a filler. Then I can re-cut only the holes needed.
Filler welded in place before grinding.
After grinding with the firewall support bolted in place.
Next up is plug welding the firewall support to the firewall sheet metal. It is clamped in place as well as a few bolts through some of the master cylinders mounting holes.
In this pic you can see that I made provisions in the support plate for manual brakes. Would just need to open up the sheet metal. Probably never happen..
Grinding the plug welds.
All smooth! Need to fill the leftover from the factory wiring bulkhead connector. The new square hole to the left, which will be behind the inner fender, is where I will use the factory style bulkhead connector for the run to the front for lighting etc.
Another filler going in.
That is the hole for the clutch master cylinder mounting.
(still need to drill out the top mounting hole.)
Decided to move over to the passenger side for a while. Filling in the various heater holes.
The firewall was flexing just a bit when I re-test fitted the Vintage Air evaporator so I decided to add a stiffener to the inside.
Now back over to the drivers side. Time to fill that hole that reminds me of a "bark-o-lounger" (old school recliner) LOL ! I don't need the upper portion which would have been for a factory mechanical clutch set up. Just need a single round hole for the steering column to come through. Started with a poster board template on the inside. This will also serve as a support for my steering column mount.
Piece cut out, bent and getting a coat of weld through primer.
Filler/support bolted in place.
Welding it in.
I made my own seal from neoprene which is sandwiched between the support and the steering column mount bracket.
This 2" hole is where in the last incarnation the EFI harness passed through the firewall. I will be using bulkhead connectors so this hole won't be needed.
Now on to the bulkhead connector mountings. I didn't want them protruding way out from the firewall so I am recessing them in about 1 1/4".
This will be the back portion where the bulkhead connectors mount.
This is one of the female halves of the bulkhead connectors.
Welding the rings to the back mounting plate.
Front view.
Rear view.
Connector inserted.
With the male portion connected.
This will be the mounting location. This spot clears any obstacles on the inside and still keeps the connectors as low as possible on the engine side. I don't mind them showing, (they are pretty cool looking!) but I didn't want them right in your face. Best compromise.
Mounting tacked in place.
Welded up.
Ground down.
Test fit.
From the inside. (still need to grind the inside smooth).
Pretty cool!
All firewall mods complete! A small bit of finish work and it will be ready for paint.
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