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Joined: Sun Sep 04, 2011 6:29 am
Posts: 309
Location: Perth Hills
Vehicle: 89 SWB vitara, g16b conversion

Post Posted: Tue Nov 11, 2014 8:39 pm 
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Crack has opened up from the firewall penetration for the cluth cable.. What have you done to plate/brace/repair this probl, heard it's fairly common. Pics would be great as it seems difficult with the contours of the firewall, crack is quite long about 40-50mm

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Joined: Mon Dec 11, 2006 10:30 pm
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Location: East Radelayed
Vehicle: SV420+SV620 Vitara's

Post Posted: Tue Nov 11, 2014 8:48 pm 
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brando93's pic attached for reference. :)
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Joined: Fri Nov 16, 2007 10:30 pm
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Location: Sunshine Coast Qld

Post Posted: Wed Nov 12, 2014 6:09 pm 
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Remove the clutch cable.
Drill a 5mm hole at the very end of the crack.
Panel beat it all flat.
Weld up the crack including the hole you drilled.

Drill 3 or 4 more 5mm holes around the big hole the cable goes through.
Make up a reinforcing plate about 70mm square with a big hole the same as the clutch cable hole.
Place plate inside firewall and plugweld through the 5mm holes.
Flapper disc it all smooth, prime then paint.
Replace clutch cable.
All done.

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