The firewall is a little tricky. There are three metal plates that need to be mated together. One across the top and then the bottom left and right which make up the foot box backing. We first mounted the firewall using heavy clamps to hold in place and outlined all the metal bars with perm marker. Then we used the provided rivet spacing tool to have 3" rivets on all the places where the firewall met the frame. Using a #11 drill bit (we had to chase these down and in the end I got some high grade ones from a machine supply store) we drilled out all the holes for the rivets on the firewall. This was a great job for my son. We then used acetone to clean up all the marks. Before installing we decided to put dynamat against the firewall. In retrospect this was a fantastic idea. Not only did it provide a solid surface for the mounting but also created a seal between the metal components. We then clamped the metal components in place and let it sit overnight. In the morning we double checked the fitment and then drilled the holes into the frame in place. As we progressed with the drilling we used an air riveter (worth the investment!) to secure the firewall. The end result is fantastic!
Mocking up the placement of the firewall. The first step is to trace the bars for drilling rivet holes. The bottom right panel (left in this picture) was very hard to get in/out and I scratched the power coating of the frame pretty bad.
After we marked the frame rails we then used the rivet spacing tool to mark the spots for drilling. A good method is to use a punch on each planned hole to avoid the drill from walking (thanks Kevin for the tip).
Reid drilling the holes.
Completed panel.
Drivers lower panel. The larger circle is for the steering. A part mounts here and caused a little bit of clearance problems. But got it worked out.
Before we started riveting we put the drilled panels back in place and then drilled holes through the frame. We purchased some heavy duty drill bits from a machine supply.
Using the air riveter is easy (and fun). Even a 9yr old can do it.
Reid did most of them.
Completed firewall.