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Firewall Rust

Discussion in 'VE Holden Commodore (2006 - 2013)' started by Rusty09, Jul 17, 2019.

  1. Fu Manchu

    Fu Manchu Well-Known Member

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    AF5075BF-8B53-41BB-8054-BBD5FE56178E.jpeg
    This the smaller insulation panel that is sandwiched between the pedal plate and the brake booster.

    859B34B0-BC30-4608-BF62-689A894B9645.jpeg

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

    Fu Manchu Well-Known Member

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    1EDFA143-0182-4DA4-9DF5-7C6B60A4FA26.jpeg
    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.

    7BE19737-556F-40EB-B792-80FB8EC6DA88.jpeg
    Looms not yet masked up.

    F8221AF1-F284-4EBF-8F01-F82246832B5A.jpeg
    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.

    E15F3615-2042-4A76-AAFE-AD7C9A80BCB8.jpeg
    The view from inside.

    6DBFEBEC-537D-468F-A191-31758A7157EF.jpeg
    Done and unmasked, looking from the engine bay.
     
    Last edited: Jul 23, 2019
  3. lmoengnr

    lmoengnr Well-Known Member

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

    rucxy Donating Member

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    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.
     
  5. Fu Manchu

    Fu Manchu Well-Known Member

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    352N Red Passion (High metallic version)
     
  6. lmoengnr

    lmoengnr Well-Known Member

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    Nice!
     
  7. Vespers86

    Vespers86 New Member

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    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
     
  8. Fu Manchu

    Fu Manchu Well-Known Member

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    91FD3E0F-7449-4418-B2CF-A3599363F87D.jpeg
    Some also had a small rubber lip that tipped water away from the cabin air inlet.

    FA2D4CE5-939F-45CE-B768-EA5CAA8D7189.jpeg 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.
     
  9. VS_Pete

    VS_Pete Donating Member

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    That support bracket is the one you can see from the front drivers side firewall right of booster near steering column?
    [​IMG]
     
  10. Fu Manchu

    Fu Manchu Well-Known Member

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

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  11. immortality

    immortality Home of the smoky breakfast Bacon! Staff Member

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    Spammer be banished!
     
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  12. Lex

    Lex Well-Known Member

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    And he was!:p
     
  13. Fu Manchu

    Fu Manchu Well-Known Member

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    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.
     
  14. VS_Pete

    VS_Pete Donating Member

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    engine bay very hard to get good pic.
     
  15. VS_Pete

    VS_Pete Donating Member

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

    VS_Pete Donating Member

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    The insulation is gone I must have been lucky about 3/4hr to get out.
    Gave it a hose too.
     
    Last edited: Aug 7, 2019
  17. Fu Manchu

    Fu Manchu Well-Known Member

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    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.
     
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  18. VS_Pete

    VS_Pete Donating Member

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

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  19. Fu Manchu

    Fu Manchu Well-Known Member

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

    Fu Manchu Well-Known Member

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

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