The earlier Chevelles are great cars, but have one major design flaw-an ugly firewall. Not only do they have a seam that runs right across the middle, there are so many tack welds the thing looks like it has a bad case of acne. Having this as a backdrop to a highly-detailed motor is just a distraction. If you just want to smooth out the spot welds and eliminate the seam, then a few skim coats of body filler and some block sanding will do the trick.
What if you want to eliminate the heater or A/C holes? Well, that used to consist of cutting a bunch of filler panels and welding them in before blocking it flat again. Luckily, there is a better way thanks to the Firewall Smoothie Panels from ABC Performance. Tony Grzelakowski from ABC is now offering a CNC laser-cut panel for '64-67 Chevelles and El Caminos that makes the task of "shaving" the firewall much easier. Tony said the Smoothie Panel allows you to create a glass-smooth firewall without custom fabrication skills. The panel is cut out of 18-gauge mild steel, which is thicker than factory metal, which minimizes the chance of warping. The panel is made to go over the top of the firewall and be welded in place. This story will cover how to install ABC's killer panel on a '66 Chevelle with some prep and welding tips as well.
 Here is the ugly firewall...  Here is the ugly firewall in question. This '66 has seen better days and was rescued right before it was turned into a dirt track racer. At some point, numerous extra holes were cut into the firewall for God-knows-what. |  The precision CNC laser-cut,...  The precision CNC laser-cut, 18-gauge mild steel Smoothie Panel from ABC Performance was created to help the guys with mild welding and sheetmetal skills produce results like a seasoned pro. Because the panel is so thick it is very forgiving during the welding procedure and will maintain its flat surface much better than a thinner piece. The panel also has small holes around the perimeter for Clecos, which help hold it in place (more on Clecos later). |  Before applying the panel,...  Before applying the panel, the firewall should be stripped down to see if there is any rust lurking under the paint, or in our case the undercoating. A wire brush on an electric grinder worked the best. |
 We didn't find any rust so...  We didn't find any rust so we used a 3M Scotch-Brite pad to scuff the area so we could put some primer on it. |  We used a can of SEM High...  We used a can of SEM High Build Primer Surfacer on the factory firewall... |  ...and the back of the panel....  ...and the back of the panel. This should prevent any rust from forming between the two pieces of metal. |
 Here is a little tip to help...  Here is a little tip to help you hold the panel in place until you can drill the holes for the Clecos: use duct tape. |  The Cleco is a blind grip...  The Cleco is a blind grip fastener that inserts into the two panels and when the pliers are released lock into the hole providing about 20 pounds of holding power. They are quicker and won't produce damage or bend the panel like a screw can. If you don't have any, ABC offers a $25 kit that you can just add to your order. |  The panel is already drilled...  The panel is already drilled so we needed to drill into the firewall so the Cleco will temporarily hold the panel in place while we weld. |