Firewall plugs
Thread Starter
CF Senior Fox Bat
Joined: Aug 2011
Posts: 3,818
Likes: 619
Firewall plugs
I have literally spent about 16 hours thus far trying to get 8 firewall plugs installed into the firewall. I have tried heating them up and applying vaseline to the end of the plug and done everything including blowing my left nut trying to get them into the firewall.
I have tried a long screwdriver with a sleave that only allowed about 1/2 inch of shaft into the hole of the plug to then push it in. Everytime I try to get the plug into the hole the end just flattens out and will not go in.
There has to be a trick to it, just not sure what it is. I tried to find some thin wall alluminum tube that I could slide the plug head into but so far nothing seems to work. I have put my full weight behind the screwdriver and all I seem to be doing is mashing the end even if I am sure the tip is in the firewall. So whats the trick?
I am trying to install the insulation, the insulation has a rigid back to it, and then about half an inch of insulation on the other side. I am begining to think they have sent me plugs that are just too short?
Any ideas or help would be appreciated.
I have tried a long screwdriver with a sleave that only allowed about 1/2 inch of shaft into the hole of the plug to then push it in. Everytime I try to get the plug into the hole the end just flattens out and will not go in.
There has to be a trick to it, just not sure what it is. I tried to find some thin wall alluminum tube that I could slide the plug head into but so far nothing seems to work. I have put my full weight behind the screwdriver and all I seem to be doing is mashing the end even if I am sure the tip is in the firewall. So whats the trick?
I am trying to install the insulation, the insulation has a rigid back to it, and then about half an inch of insulation on the other side. I am begining to think they have sent me plugs that are just too short?
Any ideas or help would be appreciated.
Melting Slicks
Joined: Apr 2010
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2018 C2 of Year Finalist
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I've only had to install a couple of the plugs myself, but I matched up a socket (the size) that would just fit the depression of the plug and used an extension to push it in. 
When I originally posted this I thought you were talking about the larger flat plastic plugs (clutch rod). If you are talking about the insulation retainer plugs, there is a tool for them:
http://www.zip-corvette.com/ProductD...GR-SR&CTitle=&
When I originally posted this I thought you were talking about the larger flat plastic plugs (clutch rod). If you are talking about the insulation retainer plugs, there is a tool for them:
http://www.zip-corvette.com/ProductD...GR-SR&CTitle=&
Last edited by Mike67nv; Mar 19, 2012 at 02:18 PM.
Drifting
Joined: Sep 2004
Posts: 1,665
Likes: 60
From: Buffalo New York
Some pictures might help us. But I replaced some grommets for my speedo and tach cables on my '66 recently. I used Syl-Glide from NAPA. Just silicone grease. As I applied pressure to the grommet I would begin to spin them as though they were threaded. Once I got an edge started the rest followed.
Dennis
PS I have a place on the river in Cape Vincent.
Dennis
PS I have a place on the river in Cape Vincent.
Race Director
Joined: Aug 2004
Posts: 15,310
Likes: 2,265
From: NorCal
Are these the thin plugs with an inner lip? If so, try using a razor blade or an Exacto knife to make a slit in the inner lip at the half way points in the circumfrence of the lip (2 slits). That way you can work the bottom half in first, and be able to see the top half still protruding. Use a thin bladed screw driver to then work the top half into place.
Good luck!
Good luck!
Thread Starter
CF Senior Fox Bat
Joined: Aug 2011
Posts: 3,818
Likes: 619
No its these $#&&@ things. They lack the "Viagara" to keep themselves sufficiently firm enough to go thru the firewall. 
If you do not heat up the head, then it just will not push through the firewall because its too firm. if you heat them up then the shaft gets to flacid If you use KY jelly or Vaseline the little guy refuses to go in. Its like a person being alergic to sex
If you use any kind of tool that goes down to the bottom of the hole thats in them, then the tool stops the head from collapsing and it still will not go in the hole.
I am personally down to one nut after exploding the other trying to get the damn things to go in. I cannot afford to lose the other.
If you do not heat up the head, then it just will not push through the firewall because its too firm. if you heat them up then the shaft gets to flacid
If you use KY jelly or Vaseline the little guy refuses to go in. Its like a person being alergic to sex If you use any kind of tool that goes down to the bottom of the hole thats in them, then the tool stops the head from collapsing and it still will not go in the hole.
I am personally down to one nut after exploding the other trying to get the damn things to go in. I cannot afford to lose the other.
Last edited by TC233; Mar 19, 2012 at 02:41 PM.
Race Director
Joined: Aug 2004
Posts: 15,310
Likes: 2,265
From: NorCal
No its these $#&&@ things. They lack the "Viagara" to keep themselves sufficiently firm enough to go thru the firewall.
If you do not heat up the head, then it just will not push through the firewall because its too firm. if you heat them up then the shaft gets to flacid If you use KY jelly or Vaseline the little guy refuses to go in. Its like a person being alergic to sex
If you use any kind of tool that goes down to the bottom of the hole thats in them, then the tool stops the head from collapsing and it still will not go in the hole.
If you do not heat up the head, then it just will not push through the firewall because its too firm. if you heat them up then the shaft gets to flacid
If you use KY jelly or Vaseline the little guy refuses to go in. Its like a person being alergic to sex If you use any kind of tool that goes down to the bottom of the hole thats in them, then the tool stops the head from collapsing and it still will not go in the hole.
Try a smaller diameter tool?
Or, try slitting (ouch!
)the head so it can collapse slightly as it goes thru the hole and then pop back into shape as it comes out the other side?
Le Mans Master
Joined: Dec 2007
Posts: 8,000
Likes: 659
From: Puget Sound
Make yourself this tool using an old screwdriver and welding a washer onto it. I believe the credit for this pic. goes to JohnZ. Warm up the plug and lube it with dish soap. They go right in.
Jim
Jim
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Le Mans Master
Joined: Feb 2008
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From: NJ Hockey beer league
Everyone has a favorite tool, mine was the high tech wooden dowel. You have to push hard. If you get it part way through, sometimes you can grab it and work it the rest of the way from the engine side. 
Pilot Dan
Pilot Dan
Thread Starter
CF Senior Fox Bat
Joined: Aug 2011
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I did the same sort of thing. I drilled two holes in a 2x4 with a cup saw. Then stacked them on a screwdriver so only about 2/3rds of the hole in the firewall plug was filled. Still could not get them thru. I am 220 pounds 6;2" and when I say, I had veins in my face from pushing, I mean it, They just will not go thru. So I must have a size too big, has to be.
Safety Car
Joined: Nov 2002
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From: minneola fl
You have to "stretch" them. You push "through" the hole so that only the tip of the retainer is going through the hole. That's where the stretch comes in. If you push on the big flat part, you'll never get them in. A screwdriver will work, but will normally blow out the end, and then it's a nightmare. Stick an allen key in the end, and push on the allen key. They pop right in.!!!!!
Mike Coletta
Mike Coletta
Racer
Joined: Feb 2008
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From: Plymouth Massachusetts
I rounded the end of a screwdriver shaft that fit into the hole in the part and used vaseline on the rubber point. The trick I used was to wrap a loop of wire just behind the pointed end which I threaded through the firewall. I had an assistant gently pull on the wire as I pushed with the driver handle. Easy as pie!
Safety Car
Joined: Apr 2009
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From: Georgetown TX
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Last resort would be to widen out the hole with a round file. Careful not to take too much out.
Team Owner
Joined: Oct 2000
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From: Washington Michigan
In the plant, we used a tool similar to the one posted in the two photos above, and we kept the retainers in a tray under a heat lamp; dipped them first into a 50-50 solution of Joy soap and water, and installed them. The guy on the inside pushed, and the guy on the outside grabbed the end of the retainer with duckbill pliers and pulled while the guy on the inside pushed - they pop right in. The tool stretches the retainer slightly, and the washer seats it against the dash mat once it's through the hole.
Thread Starter
CF Senior Fox Bat
Joined: Aug 2011
Posts: 3,818
Likes: 619
In the plant, we used a tool similar to the one posted in the two photos above, and we kept the retainers in a tray under a heat lamp; dipped them first into a 50-50 solution of Joy soap and water, and installed them. The guy on the inside pushed, and the guy on the outside grabbed the end of the retainer with duckbill pliers and pulled while the guy on the inside pushed - they pop right in. The tool stretches the retainer slightly, and the washer seats it against the dash mat once it's through the hole.
