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TROYMAN
Technical Contributor
Age:34
Posts: 2940
Joined: 07 Nov 2004
Location: South Western Sydney NSW, Australia
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 Posted: Thu Jun 26, 2008 9:46 am Post subject: FIREWALL RE-ENFORCMENT PLATE(MANUAL E SERIES) |
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this has been submitted as a tech doco a few months ago but hasnt been added yet?
due to popular demand i have posted it here...
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How to make a firewall re-enforcement plate for clutch cable on e series.
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Things needed are.
A sturdy vice.
Steel plate 3mm thick x 120mm high x 100mm across.
A Piece of steel pipe with inside diameter of 18mm.
Short piece of 16mm pipe.
Some silicon.
Tape measure or ruler.
Angle grinder.
Welder.
Center punch.
Electric drill.
2.5mm drill bit
5mm drill bit
18-20mm drill bit or hole saw for steel.
Some 8 or 10 g x16mm self-tapping screws.
And a few m5 flat washers.
I used a un-damaged firewall to mock it up on.
But in most cases the firewall is damaged that’s why I mocked it up on a good one to ensure the correct angle.
Then I measured the pieces before I welded it together.
First you need a 3mm thick x 120mm high x 100mm across flat metal plate and a piece of steel pipe with at least a 18mm inside diameter. As this will fit over the original pipe.
I also welded a 5mm length of 16mm pipe into the end of the 18mm pipe to center the cable and to Give the cable a nice seating surface.
Or you can just tack weld a washer on the end if you like
Measure 60mm from the bottom of the plate and 40mm from the right side of the plate.
Center punch and drill a 18-20mm hole which should be the same diameter or slightly smaller than the pipe.
Then measure 18mm left of the top right corner and mark it.
And from the top right corner measure down 60mm and mark it.
Then draw a line and cut across the corner with an angle grinder. This is to clear the join in the firewall.
Then cut the pipe down to 28mm in length.
To get the angle needed cut the pipe on a angle.
Measure 10mm from one end and draw a line to the other end and put it in a vice and
Carefully cut on the line.
This should give you the right angle.
Now a test fit to make sure the pipe is at the right angle
I used a artline pen and used the lid as a dowel (as it’s a perfect fit inside the factory pipe) now line the pipe up with the original pipe on the firewall.
Then tack weld the pipe to the plate with the pipe angled downwards
And mark where you want the mounting holes.
Now remove it and weld it all the way around
As I made this from scrap it had 4 large holes already in the plate but I didn’t use them as I made this so you don’t need to remove the brake booster to fit it.
The green crosses in the pic are the holes I used to mount it to the firewall
Now to test fit it to the car and make sure the clutch cable slides in and out with no obstruction. Now drill the 3- 5mm holes in the plate to screw it to the firewall...
I drilled 3- 2.5mm pilot holes in the firewall and used self-tapping screws to mount it..
Using silicon in between the plate and firewall so there is a nice seal.
Here is the finished pic
Copyright © 2008 TROYMAN, all rights reserved. |
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heartagramfan
Fordmods Parts Gopher
Posts: 68
Joined: 10 Sep 2008
Location: middle of the sticks QLD, Australia
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| Posted: Fri Oct 31, 2008 12:37 pm Post subject: |
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ok so how does the plate stay there u put screws through with nuts do you or self tappers???
my firewall has cracked really bad on mine so i am looking into this |
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TROYMAN
Technical Contributor
Age:34
Posts: 2940
Joined: 07 Nov 2004
Location: South Western Sydney NSW, Australia
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| Posted: Fri Oct 31, 2008 2:15 pm Post subject: |
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| heartagramfan wrote: | ok so how does the plate stay there u put screws through with nuts do you or self tappers???
my firewall has cracked really bad on mine so i am looking into this |
i used short self tappers with silicon to seal it 2 the firewall.. |
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phongus
Fordmods Junkie
Age:23
Posts: 8855
Joined: 17 May 2005
Location: Melbourne VIC, Australia
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| Posted: Fri Oct 31, 2008 2:17 pm Post subject: |
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...is it legal to drill into the firewall 
phong =P~ |
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TROYMAN
Technical Contributor
Age:34
Posts: 2940
Joined: 07 Nov 2004
Location: South Western Sydney NSW, Australia
View User Gallery (24)
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| Posted: Fri Oct 31, 2008 2:26 pm Post subject: |
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| phongus wrote: | ...is it legal to drill into the firewall
phong =P~ |
no i dont think so??
there are many holes in the firewall already, they are pluged up with bolts,wiring grommets ect.
the firewall is not structuall is exacly what it is named (a firewall)
its to help keep engine fumes,fire ect from entering the cabin..
aslong as any holes in the firewall are sealed i cant see it being a problem.. |
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FLASH
Fordmods - Getting Side Ways
Age:29
Posts: 819
Joined: 05 Mar 2006
Location: Sydney NSW, Australia
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| Posted: Fri Oct 31, 2008 2:53 pm Post subject: |
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The fire wall is structural, every part of a mono-C**k chassis adds to the structural integrity of the vehicle (that's why they have folds a ridges to add strength to otherwise thin steel). But small holes and so on is not an issue.
My EL had ripped a HUGE whole in the firewall when i first got it and there was no repairing that. The guy who owned it before me just had a big piece of aluminium sitting there with a hole drilled through it  .
So i made a plate up out of 10mm, cut a new piece of pipe, filed the hole to the correct angle, welded that in, then carefully and i mean carefully welded it in place. I don't think that buggers going anywhere! although i wish i had wire in the MiG and didn't have to use the stick  |
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phongus
Fordmods Junkie
Age:23
Posts: 8855
Joined: 17 May 2005
Location: Melbourne VIC, Australia
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| Posted: Fri Oct 31, 2008 2:55 pm Post subject: |
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| TROYMAN wrote: | | phongus wrote: | ...is it legal to drill into the firewall
phong =P~ |
no i dont think so??
there are many holes in the firewall already, they are pluged up with bolts,wiring grommets ect.
the firewall is not structuall is exacly what it is named (a firewall)
its to help keep engine fumes,fire ect from entering the cabin..
aslong as any holes in the firewall are sealed i cant see it being a problem.. |
As I thought...but the law, being a prick as it is, might just say other wise.
But for the safety of my firewall, I might just attempt this 
Thanks Troyman
phong =P~ |
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ef007
Fordmods Stock as a Rock
Age:21
Posts: 110
Joined: 03 Dec 2004
Location: Adelaide SA, Australia
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| Posted: Fri Oct 31, 2008 7:12 pm Post subject: |
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| Anyone want to sell me a plate ? |
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twr7cx
Fordmods - Getting Side Ways
Age:22
Posts: 10397
Joined: 15 Nov 2004
Location: Hobart TAS, Australia
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| Posted: Fri Oct 31, 2008 8:15 pm Post subject: |
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| ef007 wrote: | | Anyone want to sell me a plate ? |
Likewise. |
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