68 Firewall/Footwell Repairs Help
Thread Starter
Instructor
Joined: Aug 2009
Posts: 147
Likes: 2
From: Bargo NSW
68 Firewall/Footwell Repairs Help
Now that I have the engine out its time to have a look at a repair that looks like our old mate Bubba has done.It appears that Bubba has carried out a repair using cardboard and fibreglass.
Ive been putting off this repair because I have no idea what I'm going to find.
So today I started to remove the cardboard and start sanding back all the excess glass thats there, I have a few photos that I have taken. Open to any advice you may have.
days.
Ive been putting off this repair because I have no idea what I'm going to find.
So today I started to remove the cardboard and start sanding back all the excess glass thats there, I have a few photos that I have taken. Open to any advice you may have.
days.
Le Mans Master
Joined: Jul 2006
Posts: 8,117
Likes: 104
From: charlotte north carolina
it doesn't look too bad. possibly a small(if there is such a thing) fire. how does the inside look? if the inside looks ok, just remove the metal brackets, sand and clean the area. taper the edges of the deep voids, and build these areas up with small stips of glass and epoxy resin. i like the woven cloth because it will conform to the irregular shapes better than mat glass. when the deep voids are level with the surrounding areas, add two or three layers over the entire foot-well. then redrill the bracket holes from the inside(you'll be able to easily see the original holes), and pop-rivet the brackets back in place. if the inside needs help, just repeat. check for cracks near the headlight dimmer switch and where the gas pedal attaches. it'll be (ayers) rock solid.
Pro
Joined: Oct 2004
Posts: 573
Likes: 0
From: Stafford VA
Since you have to grind anyhow, I'd grind as much of the old repair out as I could and make sure it is fixed properly. Mine was cracked across the bottom edge and the PO repaired it with duct tape... I ground both sides back 3" or so from the crack with a right angle die grinder and 2" disc and cleaned it real good with acetone. Let the acetone flash off overnight and then started filling with layers of increasing width cloth. I only mixed a couple ounces at a time and had all my cloth pieces pre-cut to finish one layer. Did the same on the other side feathering out to the edge of the fresh fiberglass. Probably 8 overlapping layers total, at least as strong as original. Cutting a small paint brush to get short, stiff bristles helped saturate the cloth by stabbing instead of brushing. It's a messy job on the firewall side, wear old clothes and rubber gloves.
Thread Starter
Instructor
Joined: Aug 2009
Posts: 147
Likes: 2
From: Bargo NSW
Thanks for the quick replies, I think i will continue to grind back the old glass as their seems to be a lot of big air bubbles, and in those areas it hasen't stuck very well.
I'll let you know how i go.
I'll let you know how i go.
Thread Starter
Instructor
Joined: Aug 2009
Posts: 147
Likes: 2
From: Bargo NSW
Just an update pulled the carpet, and from the crack down the original footwell is gone! The light shines straight thru and you can see where the repair meets the original material. I'll now just fill the holes as best i can to make it look level and as true as possible.
Team Owner
Joined: Jul 2004
Posts: 40,383
Likes: 789
From: Redondo Beach, California
Was this related to a Right Hand Drive conversion? I seems like a good Aussie fiberglass guy could clean this up and make it look professional.
An alternate would be to get some fiberglass firewall salvage parts. J&D Corvette in Bellflower Ca has a lot of salvage parts and also manufactures fiberglass panels. I would guess, if it came down to it, they could take a salvage firewall and duplicate the portion of the firewall you need. My experience is that they are easy to work with. BTW: Bellflower is about 25 to 30 miles from Los Angeles International Airport. J&D ships a lot of salvage Corvette stuff overseas. I would expect a few $$$ and Bob's your uncle.
An alternate would be to get some fiberglass firewall salvage parts. J&D Corvette in Bellflower Ca has a lot of salvage parts and also manufactures fiberglass panels. I would guess, if it came down to it, they could take a salvage firewall and duplicate the portion of the firewall you need. My experience is that they are easy to work with. BTW: Bellflower is about 25 to 30 miles from Los Angeles International Airport. J&D ships a lot of salvage Corvette stuff overseas. I would expect a few $$$ and Bob's your uncle.
Le Mans Master
Joined: Jul 2006
Posts: 8,117
Likes: 104
From: charlotte north carolina
i believe that if the exterior is strengthened with a few layers of glass, you'll be ok. worst comes to worst, build up the exterior, then remove as much of the old interior patch as possible and add glass as needed. i had to repair similar damage in my 70, and it's solid now. i made a matrix with cardboard covered in plastic drop cloth material to act as a form because a large area just fell away as i was preparing for the repair.
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Thread Starter
Instructor
Joined: Aug 2009
Posts: 147
Likes: 2
From: Bargo NSW
Was this related to a Right Hand Drive conversion? I seems like a good Aussie fiberglass guy could clean this up and make it look professional.
An alternate would be to get some fiberglass firewall salvage parts. J&D Corvette in Bellflower Ca has a lot of salvage parts and also manufactures fiberglass panels. I would guess, if it came down to it, they could take a salvage firewall and duplicate the portion of the firewall you need. My experience is that they are easy to work with. BTW: Bellflower is about 25 to 30 miles from Los Angeles International Airport. J&D ships a lot of salvage Corvette stuff overseas. I would expect a few $$$ and Bob's your uncle.
An alternate would be to get some fiberglass firewall salvage parts. J&D Corvette in Bellflower Ca has a lot of salvage parts and also manufactures fiberglass panels. I would guess, if it came down to it, they could take a salvage firewall and duplicate the portion of the firewall you need. My experience is that they are easy to work with. BTW: Bellflower is about 25 to 30 miles from Los Angeles International Airport. J&D ships a lot of salvage Corvette stuff overseas. I would expect a few $$$ and Bob's your uncle.
