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Vitara crack in firewall
https://auszookers.com/forum/viewtopic.php?f=5&t=48411
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Author:  brando93 [ Tue Nov 11, 2014 8:39 pm ]
Post subject:  Vitara crack in firewall

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

Author:  atari4x4 [ Tue Nov 11, 2014 8:48 pm ]
Post subject:  Re: Vitara crack in firewall

brando93's pic attached for reference. :)
Image

Author:  want33s [ Wed Nov 12, 2014 6:09 pm ]
Post subject:  Re: Vitara crack in firewall

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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