Firewall Rust

This the smaller insulation panel that is sandwiched between the pedal plate and the brake booster.



A close up of what was behind it. That fastener had split as the threaded stud rusted and expanded.

 

The view once it was out, from inside.

Then clean up the firewall itself. Used ranex to remove surface rust, then a primer, then a few coats of colour, then 4 coats of clear.


Looms not yet masked up.


Engine bay masked up, looms taped and masked.
I used bubble wrap because it helped my anxiety doing this job. I could pop the bubbles for therapy.


The view from inside.


Done and unmasked, looking from the engine bay.

 

Hehehehe… Luv bubble wrap for therapy! What colour is you car, 'Sizzle'?

 

That's the pesky bugger.
I didn't remove the wiper assembly or the plastic cowling. Just persevered with what little room I had to work with.
I think I was lucky in the fact that my insulation was disintegrating which made it easier to remove.

 

352N Red Passion (High metallic version)

 

Nice!

 

I’ll have to check my 08 commodore to see if it’s got the same problem as yours, another annoying thing with the ve commodore is the plastic panel that sits on the bottom of the windscreen that catches the water that runs off the windscreen, on some ve’s the water just runs under the plastic cowling where it doesn’t seal against the windscreen properly and goes into the engine bay and down the fire wall, mine does it a little bit but not as a bad as other ve’s I’ve heard of, this isn’t the cause of your rust problem though, shame cause their nice cars otherwise

 

Some also had a small rubber lip that tipped water away from the cabin air inlet.

The series 2 has an adhesive foam seal along the windscreen base that the cowl pushes down on to manage that. You can see it in this picture.

 

That support bracket is the one you can see from the front drivers side firewall right of booster near steering column?

 

That is possibly the greatest spam placement in this forums history.

 

And he was!

 

Is that from inside or outside the car?
If that’s from the engine bay, I think i have put the steering column seal on back to front.

 

engine bay very hard to get good pic.

 

I just ordered a bracket 92192901.
I`ll get a diagram and put it up

 

The insulation is gone I must have been lucky about 3/4hr to get out.
Gave it a hose too.

 

I noticed that on your MY12, that bracket seems to have a white seal under it? My MY07 didn't.
I have double checked the column seal against eBay photos. Looks like it is in correctly. The MY12 seems to have a better designed seal though. Would have been good to install a better seal on mine.

 

I had a brake fluid leak and booster got a hole.
Booster 7 weeks to come from USA.
Going to panel shop on Monday.

 

Would be a good chance to fit up a VF booster and master cylinder, which improved brake feel over VE

 

Wipe some ranex rust buster over that paintwork, wipe off the surface rust. Maybe give it a spray.