55 Nomad Bulkhead/Firewall Problem

[gazztan]

Hi Everyone,

I'm after some advice.
I've just received a 55 nomad which I purchased from California and shipped home to Australia.
I know it's a risk purchasing a car unseen but after discussion with the owner was pretty content with its condition. Well after removing the front clip I have found some nasty surprises.tdi
Has anyone repaired these sections in the bulkhead before, did you get sections cut from a donor vehicle or fabricate?
Any help appreciated!!
Thanks.

Gary.

[carls 56]

hi gary. doesn't look to bad. congrats on getting that nomad. :five:..............:sign0013: have never repaired that, but this will move it back to top to get some answers. :anim_25:

[Hotroddder]

The outer cowl side is being reproduced and fit pretty well. You would only need to use the bottom section as far as I can see. The interior parts could probably be fabbed up since they are hardly or never seen when the car is completed. Just start trimming until you get to solid metal, then start making sheet metal parts from the inside out until done.

Sounds simple doesen't it...

Actually it is not too bad, and if this is the extent of rust repair needed on the Nomad, yuo have a very solid car...

Good luck

Hotroddder

[boz2318]

Gary,
go back to Metal Fabrication and Repair Questions
and then to lower cowl inter hinge area repair.
Robert (MP&C) has photos of all of it.
I have Just finished doing this repair it is a lot of work.
I did mine a little different here and there but for the most part
I went by what Robert showed.
have questions drop me a line.

GOOD LUCK.

[Chevynut]

Wow, that looks like a lot of repair work, but it can be fixed. Do like Hotroddder said, and start rebuilding from the inside.

[boz2318]

Gary,
I was thinking that you should remove the cowl panel because when I did
I found that the rain channel needed to be repaired as well as some rust holes. Eckler's had the best price on the cowl panels.

[tjsdelivery]

It looks like that extent of rust through may reach to your joint plate and rocker area. This is a structural area for the front and needs to have the most attention paid to it. The rest around it is pretty much cosmetic. I fabbed my own cowl panels and they turned out pretty good. Plus, no one ever sees them once everything is buttoned up again.

[madtony56]

Congrats on the `55 nomad. This car will be the talk
of the town down under, when it is finished.
The hole looks bad, but it is in a place you can get to.
Like what was stated earlier, cut the bad metal out
until you get to good steel. Then fill the hole with good
steel.
:anim_25:
keep us posted on the progress.
:wavey:

[Kiwi56]

Gary,
go back to Metal Fabrication and Repair Questions
and then to lower cowl inter hinge area repair.
Robert (MP&C) has photos of all of it.
I have Just finished doing this repair it is a lot of work.
I did mine a little different here and there but for the most part
I went by what Robert showed.
have questions drop me a line.

GOOD LUCK.

Gary,
Here's a link to the post mentioned abovehttp://www.trifive.com/forums/showthread.php?t=31244
it's very detailed and well worth a look
good luck with the repair ... hey anything can be fixed
Love to see some full pic's of the Nomad.

[gazztan]

Gee, thanks for all the advice guys, that great!!:)
I was feeling a bit down hearted when I discovered this rust but your encouragement has got me motivated to tackle this job.
That thread by MP&C is fantastic, pics and an explanation make life so much easier.
You're right, this is a pretty unique car to have in Australia and I can't wait to get her on the road. I feel pretty lucky to have it, now it's time to get my hands dirty.
Thanks again fellas!!:tu

Gary.

[nomadawhat]

Gary

My 55 was rusted in the same area. When I took the front clip off I found that patch panels had been welded over the rusted out areas, and the patch panels had also rusted! Mine wasn't as bad as your or MP&C's, but I tackled mine by getting another firewall/dash cut out complete - back in the days when you could find one complete. I unpicked all the spot welds for the covers over the air vents, and then unpicked all the spot welds holding the whole firewall in - it had been badly converted to RHD, and had had several sets of holes for brake boosters etc, so I thought iy would be easier in the long run to unpick what the factory had done, and then put it all back together. Luckily there was minimal rust in the metal under those covers, and it went back together, according to plan. It can be done. good luck with the project

Des