Vintage Air Firewall Installation

[Doppleganger]

So I'm getting the holes drilled and such for the VA air it will eventually have - with no dash in the way its alot easier. They give you a plate/template for the heater and ac hoses. Mine has a block off for the whole right side (cleaner looking). I transferred the hole location to the firewall as I dont need their plate. 1 hole is 5/8''; 2 holes are 1-1/4" - easy enough. But 2 of them mic at .920 (59/64?). Anyone else encounter this - and if so, what did you use? I would go 7/8 or 1" if I thought there would be no issues.

FWIW: used a step drill to get it close then a cone shaped grinding stone to get it exact.

 

[CalSgt]

So I'm getting the holes drilled and such for the VA air it will eventually have - with no dash in the way its alot easier. They give you a plate/template for the heater and ac hoses. Mine has a block off for the whole right side (cleaner looking). I transferred the hole location to the firewall as I dont need their plate. 1 hole is 5/8''; 2 holes are 1-1/4" - easy enough. But 2 of them mic at .920 (59/64?). Anyone else encounter this - and if so, what did you use? I would go 7/8 or 1" if I thought there would be no issues.

FWIW: used a step drill to get it close then a cone shaped grinding stone to get it exact.

Pictures or it didn’t happen!

I never measured the holes on mine but getting all of the hard line from the heater core and evaporator to exit clean was a PIA. It probably wouldn’t hurt for the holes to be slightly larger, you’ll just need to get some grommets that fit whatever hole size you choose.

If you go to large you may need to seal up the gaps around the lines from inside the cab.

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[Doppleganger]

Pictures or it didn’t happen!

I never measured the holes on mine but getting all of the hard line from the heater core and evaporator to exit clean was a PIA. It probably wouldn’t hurt for the holes to be slightly larger, you’ll just need to get some grommets that fit whatever hole size you choose.

If you go to large you may need to seal up the gaps around the lines from inside the cab.

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Were the 2 holes for the air box mount hard to locate? Were they original holes or something they had included with that panel?

Not having a dash in the way makes this a whole lot easier. lol

 

[CalSgt]

Were the 2 holes for the air box mount hard to locate? Were they original holes or something they had included with that panel?

Not having a dash in the way makes this a whole lot easier. lol

I can’t remember for sure but I think i had to drill those. I used the VA trim plate to locate them, IIRC a few of the holes in the plate used factory holes to locate and the remaining holes were supposed to be drilled

 

[fnny6770]

Did your truck originally come with air conditioning?

 

[Doppleganger]

Did your truck originally come with air conditioning?

Mine? Sort of. Was a dealer installed mess that was missing half its components. But nothing OE.

 

[CalSgt]

I’m assuming you bought the kit for a non A/C truck

I used the 3 factory holes and the pinch seam to locate the mounting plate, marked the 2 mounting holes, and marked the plate on the inside of the cab where it covers the original square heater hole.

Took the plate back off, drilled the mounting holes and welded the rest of them shut. Then cut out the patch for the square heater hole and welded it in too. A little body filler and Bob’s your uncle!

I’d still like to se a picture of your firewall

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[Old Guy Bill]

It's not that critical, the rubber grommets allow some movement in the lines.
I did fab a small bracket to hold the heater line valve to the fender well, I didn't like it hanging on the hose.

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[Doppleganger]

I’m assuming you bought the kit for a non A/C truck

I used the 3 factory holes and the pinch seam to locate the mounting plate, marked the 2 mounting holes, and marked the plate on the inside of the cab where it covers the original square heater hole.

Took the plate back off, drilled the mounting holes and welded the rest of them shut. Then cut out the patch for the square heater hole and welded it in too. A little body filler and Bob’s your uncle!

I’d still like to se a picture of your firewall

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Yes - non AC kit.

I have to replace the roof skin - the back of the cab angle doesn't match up well so am having a shop do it in a couple months. Fella there (80 yrs old....hands down the best in the area) said he's done these before and you have to tweak the joining parts a bit - I'm not going near that. So in the meantime I'm drilling all the holes before hand so they can be primer and painted (no exposed metal from drilling). Not having the dash in the way is a freebie. Funny - the guy who made these firewall panels had an option for pre-drilling these holes. Woulda-shoulda-coulda.

I have seen several who do these VA installs btch about having to contort themselves to get the bolt, spacer and washer in behind the airbox, and wish they had a 'stud' to hang it on. Kind of see what they mean so might drive off that bridge when I come to it.

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[CalSgt]

Yes - non AC kit.

I have to replace the roof skin - the back of the cab angle doesn't match up well so am having a shop do it in a couple months. Fella there (80 yrs old....hands down the best in the area) said he's done these before and you have to tweak the joining parts a bit - I'm not going near that. So in the meantime I'm drilling all the holes before hand so they can be primer and painted (no exposed metal from drilling). Not having the dash in the way is a freebie. Funny - the guy who made these firewall panels had an option for pre-drilling these holes. Woulda-shoulda-coulda.

I have seen several who do these VA installs btch about having to contort themselves to get the bolt, spacer and washer in behind the airbox, and wish they had a 'stud' to hang it on. Kind of see what they mean so might drive off that bridge when I come to it.

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Good luck Sir!

If your kit still has the plate you could make a cardboard template of the holes you need to drill and the factory holes. Then transfer the marks to the inside of the firewall and drill the holes

 

[Doppleganger]

Good luck Sir!

If your kit still has the plate you could make a cardboard template of the holes you need to drill and the factory holes. Then transfer the marks to the inside of the firewall and drill the holes

The holes for mounting the airbox are on the panel?

 

[CalSgt]

The holes for mounting the airbox are on the panel?

I’m not 100% certain but I think these three holes are the factory holes used to align the mounting plate from the engine bay side.

If you make a template with these holes and maybe add in the holes for the lines you should be able to get the two A/C mounting holes marked.

Use the vintage air mounting plate as a guide for the template, a beer box or cereal box will make good template material. Sometimes I use a bolt and a hammer to punch out the holes in the cardboard, I use a scrap piece of wood as my backer.

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[Doppleganger]

I think these are the holes they used (lines up perfectly with the bracket). They were factory holes covered by the new plate. The spacers are to bring it out enough that it doesn't hit the bulkhead under the windshield. I would love to get the lines ready to go but this box isn't going in before at least Spring - its vac'd now - hate to break the seal.

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[kkgp81]

The holes in the cab aren't that exact. The holes in the plate is what your rubber grommet locks into. The AC/non AC part of the kit has nothing to do with the firewall. If you aren't using the plate then match the plate hole diameters and rock on. I screw the plate on then use a hole saw to locate the holes then pull the plate and use a different hole saw to kick the 1-1/8" and 2" holes. You will also need to drill the holes that hold the unit to the firewall

The 2:25 mark here shows the firewall on the last install I did.

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Currently have a plate in the shop for the current project so I don't have a system sitting on the shelf burning down the warranty.

 

[Doppleganger]

I put some masking tape down then stuck the plate on with rare Earth magnets - leveled it - didnt move. Took a sharp pencil and traced the 5 holes. Used a compass and found dead center on all of them. An 1/8" drill for starters and those holes are exactly located and sized where the plate would have put them.

I didnt need the plate or the brackets they included for the compressor (used a different one). Only thing left is to transfer the holes for the airbox plate.

This kit was delivered 10-09-2018 and I just opened it. lol