My firewall is rotted. The photo is of the firewall area behind my intake manifold. There is more rot in the area to the left of the photo. I would also have to assume that there is rot on the inside of the cowl area also. Time to pull the cover off. I am looking for suggestions on how to repair this?

http://www.flickr.com/photos/40952238@N04/9289124286/

 

Your biggest concern should be down lower where the firewall rolls into the floor. If you have that, may make it hard to justify fixing it per the cost.
As for the rest of the rott it will need to be cut out, plated then treated.

 

Scrape, rust reform, spray paint... sell.

 

I was thinking of using this kit to do the repair: Eastwood Seam Sealer and Rust Encapsulator Kit

 

no need to get fancy just use some rustoleum rust restorer, you can get it at any hardware or paint supply

 

Wire brush it off.
Put on that sealer that seals the rust.
Or ---
Cut it out.
Put aluminium over it and just glue it in with epoxy.

 

Looks like I will be doing a combo of repair methods.

I started wire brushing the area last night and I now have a half dollar size hole to the cowl.

My plan is to finish wire brushing the area with a dremel/drill then paint the area with Loctite Extend and epoxy (JB Weld) Aluminum pieces over the hole (both sides).

I still need to pull the cowl trip off to see what it looks like on that side.

 

Have you looked farther down on the fire wall to make sure there is no rust there? That is a common place and it can do a lot os structerial damage to the bulk head. Any rust like that needs to be cut out and plated and don't forget to treat the inside of the panel also or it will come back.

 

2nd Mike's posts... if you try to half *** the repair it will bite you later. Rust is like cancer and it spreads. Rust reformer will buy you time, but it will come back.

 

Scrape, rust reform, spray paint... sell. (accentuate the final period)