{"id":340,"date":"2011-02-03T10:17:34","date_gmt":"2011-02-03T15:17:34","guid":{"rendered":"http:\/\/www.monocoque-metalworks.com\/main\/?p=340"},"modified":"2011-04-13T13:26:05","modified_gmt":"2011-04-13T17:26:05","slug":"1968-22-firewall-repair-section","status":"publish","type":"post","link":"https:\/\/www.monocoque-metalworks.com\/main\/2011\/02\/1968-22-firewall-repair-section\/","title":{"rendered":"1968 2+2 Firewall Repair Section"},"content":{"rendered":"
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This is the photo from the advertisement I ran across - the poster was looking for a used section to help here - I'm sure they never imagined I was busy at work across the Atlantic trying to form this exact piece...<\/p><\/div>\n

In our ongoing efforts on reproducing all E-Type panels, one of the biggest challenges has been the firewall recesses.\u00a0 I have tried to get these right with mutiple machines and methods over the past few months, and I FINALLY succeeded on the fourth attempt!\u00a0 I won’t get into how much I spent on tooling to make this one simple panel below – or how it’s done – that’s top secret stuff…<\/p>\n

Anyway, I ran across an ad on the internet from a gentleman in Ireland looking for a repair section for the firewall on his Series 1.5 2+2.\u00a0 Just like the ’66 FHC donor tub in our shop, his firewall had been cut to install an aftermarket AC unit – and I’ve seen this on other firewalls over the years as well.\u00a0 He was looking for a section of a used firewall, as E-Type firewalls and cowls have always been “the Holy Grail” – it’s the one thing you just can’t pick up the phone and order – until now…<\/p>\n

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The completed piece - I'm really proud of this one. E-Type firewalls have been unavailable throughout my entire life - not any more!<\/p><\/div>\n

I formed this patch panel from new cold-rolled steel – it is EXACT in every dimension.\u00a0 It’s still in transit as of this writing, but I know he’ll be very pleased.<\/p>\n

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Looks even better upside-down for some reason... The recess is EXACT - it is the correct size, shape, depth, corner radius, and the shape of the slope down into the recess is also exact. I was actually running around the shop waving this in the air when it was finished!<\/p><\/div>\n

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Of course, to make it perfect, it needed the welded nuts for the throttle linkage brackets and the washer-bottle. These are the correct thread, although the shape of the outer portion of the nut is a little different (the square ones are easier to tack on when they are that small...) These are un-seen, so I did take that liberty...<\/p><\/div>\n

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We've already formed the large backside of the cowl assembly, and most of the smaller internal gussets, etc. Now that the firewall recess problem is resolved, we'll soon have a full firewall formed and be able to assemble this all-new E-Type cowl assembly!<\/p><\/div>\n

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The panel finally arrived in Ireland, and here it is fitted up against the damaged firewall. I'm very pleased with the way this turned out - it's a dead match in all dimensions, although there did seem to be a slight depth difference with the recess on the other side of this car's firewall - the LH side was 1\/16" deeper than this repair piece. The repair piece is IDENTICAL to the firewall it was patterned after, but after going around the shop, I can see that there is about that much fluctuation from car to car... Luckily, the way the tooling is designed, I can adjust this depth on future repair pieces to match the car being repaired.<\/p><\/div>\n","protected":false},"excerpt":{"rendered":"

In our ongoing efforts on reproducing all E-Type panels, one of the biggest challenges has been the firewall recesses.\u00a0 I have tried to get these right with mutiple machines and methods over the past few months, and I FINALLY succeeded … Continue reading →<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":535,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[16,8],"tags":[],"class_list":["post-340","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-allposts","category-custom-panel-fabrication"],"_links":{"self":[{"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/posts\/340","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/comments?post=340"}],"version-history":[{"count":11,"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/posts\/340\/revisions"}],"predecessor-version":[{"id":691,"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/posts\/340\/revisions\/691"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/media\/535"}],"wp:attachment":[{"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/media?parent=340"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/categories?post=340"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.monocoque-metalworks.com\/main\/wp-json\/wp\/v2\/tags?post=340"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}