Firewall flex
 

I addressed this a few years back but I now must deal with it.. My firewall at the clutch master cylinder is cracked and flexing.. I noted that someone makes a plate to be welded in there. Does anyone know where I can contact this person or does someone have a reasonable alternative?

if this is what you're after a search of the forums might find where i saved this from.
http://forums.pelicanparts.com/uploa...1373452819.jpg

I dont see dimensions.. Is this the only one out there? I did a search but did not find it..

It is the only one I know of. The one I'm mailing you is the same, but actual size so no dimensions given.

Aha.. You are HICKS on Rennlist! Eureka! I am sometimes a bit slow on the uptake!!

Hello again Gordon, I troll both places. The template will be in the mail tomorrow.

Also Gordon, the plate is 3mm thick aluminum and there is a three way mix to install. They say to use the weld-bond with the welding or bolts or rivets. Disregard options I sent you via PM on rennlist.
1. SEM # 39537 weld-bond adhesive.
2. Mig/Tig weld
3. 15qty. M8x1.25 x 25 bolts and locknuts.
4. 15qty. Pop #ssd 85 ssh 1/4" x .613 SS closed-end rivets.

Hit me up with any questions, and when you get the sheets.

I will PM you as soon as I get it..Thanks Chicks!!

Keep in mind that if you go the wedding route that the body is entirely galvinized steel and the fumes are very bad for you.

Personally I'd remove the hydraulics, remove all paint from the area of installation, cover the contact area in JB weld, rivet it together, paint the area with an etching primer and then use the closest rattle can paint to your color and then make a document for your records detailing the operation for future reference and for resale. Don't forget to replace the paper gasket on the clutch MC.

Not seen our heard of this issue in my many years of ownership,interesting,was the problem corrected on the later cars?.
Can see it being easy to fit.

You are going to need to create an 11ish degree angle for the clutch MC or the input shaft will not have the correct angle causing a rub resulting in MC failure. Check to make sure you don't have cracks along the firewall/fenderwell angle or the whole assembly will be moving as you push the pedal. It can be fixed with an angle iron bolted to the plate and inner fender.

HUH?? This does not compute!

Look at the firewall where the clutch MC sits, there is an angle there for the mounting surface of the clutch MC. When the firewall plate is installed the mounting surface for the clutch MC is now flat. You will need to put in a 11deg shim to create the correct angle or the clutch MC pushrod will rub causing premature MC failure. This is a known problem with the design of the fire wall plate.

Gordon,

I'm not sure if you are still interested in the firewall brace plate, but we are now making one. I got a copy of the drawing from Chicks too, but I found out that the drawing was wrong. Don't make a plate based on that drawing. I don't know why, but the holes are in the wrong spot. Also, the way that plate was made, you have to remove the AC lines to install it. Our plate is shaped a little different and can be installed without removing the AC lines. Here is a link for the firewall brace.

Fire wall brace - only944.com

Viva la Only944.com!
Keeping our favorite horses on course.

Just fought through this. What a pain!

http://i124.photobucket.com/albums/p...ps3991f111.jpg

http://i124.photobucket.com/albums/p...ps4ad1e448.jpg

http://i124.photobucket.com/albums/p...psbe62f1af.jpg

http://i124.photobucket.com/albums/p...ps3e9e3d63.jpg

http://i124.photobucket.com/albums/p...ps30a06cdf.jpg

http://i124.photobucket.com/albums/p...ps9825ce51.jpg

hi gordon. looks like you have the solution. the firewall cracked in my 84 944 about 8 years ago.
i looked closely at how it had flexed, then cracked. also took stock of surrounding area.
im a tool and die maker, so had no problem fabricating a three point bracket to insert in place of rusted out thin sheet metal.
i used stainless steel,3mm thk, laser cut to my sizes. i bolted it in place, using 6 bolts spread out, and 8 years later, no issues.
before i discovered the rotted out metal, i thought my clutch was going, but it was the cylinder moving fwd with the force of the pushrod!.
once you get the plate in position and welded in, you will have no more problems!
best of luck.

One thing to remember if welding in the repair plate is that any wiring has to be pulled back at the firewall under the dash to prevent damage.

Cheers,
Larry

Nice work, Rasta

+1