Filling firewall holes? Ideas?

[royt440]

What have you used/recommend to fill in unused bolt and screw holes in the firewall?  Also, would there be a good method to fill in the larger openings (A/C blower and inlets, heater connections)?  I've seen one of the Saturday car shows use a welder but I don't have one.
Thanks for any replies.  I want to clean up the engine bay before reinstalling the motor.

[greatwn73]

You can get rubber body plugs in various sizes (like in the trunk and floors) at body shop supply store. Smaller holes can be filled with the plastic grommets used as retainers.

[hutch]

If you dont have a welder then see if you can rent one.  I would not use any other method to fill fire wall holes than weld.  Body filler or fiberglass will just work its way loose over time and you will get your holes back.  You can get a cheap torch and some lead stock and try to fill it in and work it with a grinder.

[1st_charger]

I didn't want to permanently close mine off in case I decided to put AC back in some day so I made a pattern and had a sheet of aluminum cut to cover the holes that I didn't need and used the original firewall bolt holes and a  little sealer to secure it! Also decorated it a little to!

[royt440]

Thanks for the tips.  It's time I bought a welder anyway.  From what I've read, one of the 110volts should be fine for sheet metal.  I think it was HorsepowerTV that had demonstration.

That MOPAR panel looks great, as does the whole by

[MoParMetal]

Thanks for the tips.  It's time I bought a welder anyway.  From what I've read, one of the 110volts should be fine for sheet metal.  I think it was HorsepowerTV that had demonstration.

That MOPAR panel looks great, as does the whole by

no less than 120 amps!!!

[royt440]

Any recommendations on brand or model?  I actually have space in the fuse panel for a 220 outlet.

[MoParMetal]

Any recommendations on brand or model?  I actually have space in the fuse panel for a 220 outlet.

mig welder at least the millermatic 140. if you have a little more cash get the millermatic 180.

quality stuff made in the USA!

[68 CHARGER R/T]

yeah that's your best bet to get a welder, even the lincoln are a good choice brand .just get a piece of flat copper atleast  1/2" thick place it behind the hole and have someone hold it for you in place while you fill it. easiest way because copper melts at a way hotter temp.just keep your amps set the right voltage otherwise you will warp the firewall. been welding for 15 years so far so seen enough things out there .

[MoParMetal]

yeah that's your best bet to get a welder, even the lincoln are a good choice brand .just get a piece of flat copper atleast  1/2" thick place it behind the hole and have someone hold it for you in place while you fill it. easiest way because copper melts at a way hotter temp.just keep your amps set the right voltage otherwise you will warp the firewall. been welding for 15 years so far so seen enough things out there .

the copper is a very good idea. also make sure that its clean. the cleaner it is the better the weld will come out.

[royt440]

Appreciate the input.  I've heard good things about the Miller units.

[MoParMetal]

Appreciate the input.  I've heard good things about the Miller units.

i use em just about everyday 

my favorite so far is the syncrowave 350... tig is so awesome 

[charger2fast4u]

I didn't want to permanently close mine off in case I decided to put AC back in some day so I made a pattern and had a sheet of aluminum cut to cover the holes that I didn't need and used the original firewall bolt holes and a  little sealer to secure it! Also decorated it a little to!

did you use one piece of aluminum to cover all the holes or did you cut out acouple pieces to fit each hole individually?

[1st_charger]

one piece of aluminum, One of the holes you cant see as I mounted the ECU over it.

[MoParMetal]

one piece of aluminum, One of the holes you cant see as I mounted the ECU over it.

that is one cherry looking engine bay!