Impreza Group-N project.

[Aram]

Got me some new saws today, much better.

I have to cut a few holes in the firewall, one for the airco, one for the heater itself and 2 more for engine looms.
The new-age models have different connection terminals for the airco and heater so I have to adjust everything.
I knew this was going to come because I had the same problems with the build-up of my other project, that's why I started with the dash on this project, good to have it out of my way.

It might look simple to cut a few holes in the firewall and it is, but there are other problems.
There have been made all kinds of foldings (not sure if this is the correct word for it) pressed into the metal of the firewall, this is for strength and against resonation.

The airco terminal has to be tight to the firewall to prevent leakages so I have to make it flat.
But when they press the folds into the metal it stretches it a litlle also, so when you try hammer it flat there is some material left, which has to go somewhere.
So when you hit the firewall in one place it bounces back somewhere else.

To cure this I have made cuts into all the stressed places, this relaxes the metal.

So I had made a nice fitting hole:




I had already fixed the heaterunit, into which the airco unit is built, so the position of the connection terminal was final, I had to make the firewall fit around it.

The firewall had to be repositioned back and forth a bit to get it to fit the connection terminal, but due to the stresses the hole I first cut didn't come out right.
So I had to make it bigger:




I increased the hole a bit more because I decided that the coverplate was going to be bigger and incorperate one of the engineloom holes too:




I used some packing foil as blueprint:




Which I used for cutting it out in cardboard:



Et viola:




After that I started cutting holes for the heater connections:



Then the day was over.