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November 17, 2018

Filed under: 77bug — vkoser @ 10:24 am

I got the replacement firewall installed last night and put about 40 spotwelds on it.  Seems very stable, I only welded the external flange thats under the gas tank for now.  I may try welding the internal flange after the heater channels are replaced but I think I may need to move around the internal half of it a tad to match up with the heater channel replacements so left it loose for now.

The spotwelder is awesome for this kind of work since the steel on the replacement panel is so thin.  If you get it clean its pretty much a no brainer to weld it right.

Clamp down flip the switch and zot.

Picture of the firewall looking down through the gas tank hole:

new firewall picture

And a picture from inside the car, camera phone and dark rooms dont mix:

new firewall inside car view

Average Rating: 4.5 out of 5 based on 185 user reviews.

November 17, 2018

Filed under: 77bug — vkoser @ 11:01 pm

Got the firewall out last night.  Wow what a lot of work.  Lots and Lots of spotwelds to drill out as well as tons of seam sealer.

Note:  plasma cutter + wads of old 1977 seam sealer == fire

here is a shot of the hole where the new one will go in

firewall picture from front

Here is another picture from the underside

firewall inside

and the final picture from the inside looking forward

firewall inside 2

for part 2 I’ll be installing the new one

Average Rating: 5 out of 5 based on 230 user reviews.

November 17, 2018

Filed under: 77bug — vkoser @ 2:40 pm

Almost done up front, got the new master cylinder mount welded in.  I ended up cutting the main hole with the plasma cutter a bit small and grinding it out to fit.  I found a socket in my 3/4 set that matched the master cylinder diameter perfectly so I didn’t have to keep jamming the soft rubber boot in and out for test fitting.

img_0762-640.jpg

I also got the wraps around the front where the beam mounts and got those drilled out with pilot holes.  Now that they are drilled I’ll take a large big and bore it out and insert a steel sleve int here for the bolt to go through.  Should end up being uber strong.

frame head side view

Average Rating: 5 out of 5 based on 291 user reviews.

November 17, 2018

Filed under: 77bug — vkoser @ 9:49 pm

got all the metal on the frame head face. I “might” do a bit more grinding on it but maybe not. The sockets are in decent shape so I might just drill it out from the backside and paint it. I’m honestly getting pretty ready to put the car back together but am resisting the urge to hurry the rest.

frame head face progress

once again for reference here is the before shot:

Somehow I forgot to add the brake lines to the cip1 order so I still need to order those and pay more shipping dang.

Average Rating: 5 out of 5 based on 160 user reviews.

November 17, 2018

Filed under: 77bug — vkoser @ 9:43 pm

some of the skinning of the frame head. The whole front will be skinned when done the middle sections are still waiting for skinning. Going to put a sleeve in the bottom mount hole since the threads are just gone…

frame head skinning

thumbnail of the before here :

I also got in the front firewall in the mail today. It was supposed to just be the lower section but it appears they sent the entire thing so hey I’m not complaining…. I ordered brake lines too but somehow i must have not gotten them on the order so I’ll have to order those soon so they are here when the pan is done being painted.

front firewall on pan

Average Rating: 4.9 out of 5 based on 272 user reviews.

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