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1967 Nova custom firewall fabrication smooth sheet metal delete panels welding shaping firewall modification
1. MetalWorks Classic Auto Restoration’s Dayton Eitner was the craftsman responsible for the repairs to the body and modifications made to the firewall, cowl, and dashboard of this 1967 Chevy II.
Making Less Become More
MetalWorks Cleans Up the Cowl, Dash, and Firewall on a 1967 Chevy II
By Ron Ceridono Photography by Chadly Johnson
W

alk around any car show or cruise-in and you’ll likely find examples of two distinctly different approaches to construction. Some builders focus on adding eye-catching elements to their cars that are impossible to miss. Others opt for more subtle modifications, coupled with scrupulous attention to detail; those are the cars that always get a second or third look and make gearheads smile. Those are the kind of modifications MetalWorks Classic Auto Restoration in Eugene, Oregon, is known for and will be making to the 1967 Chevy II shown here.

When the first-generation (1962-65) Chevy II was introduced it was intended as a reasonably priced, no-nonsense economy car. For the first two years of production, Chevy II engine choices were modest, as economical operation was the goal. Buyers had their choice of two inline engines: a 153ci four-cylinder and a 194ci six-cylinder. But in 1964 Chevrolet saw an opportunity to provide performance enthusiasts a mini muscle car and introduced the 283ci V-8 as an available option. In 1965, both the 250- and 300hp 327 became available, then Chevrolet completely redesigned the second-generation Chevy II for 1966. There were minor trim changes for 1967 and the 350hp 327ci V-8 became available, but those efforts were overshadowed by the introduction of the Camaro that same year. Nonetheless, the first- and second-generation Chevy IIs were popular then and are highly sought-after today.

Something we should explain is when a Chevy II is a Nova and when it isn’t. From 1962-67 the Nova designation simply signified the upgraded Chevy II trim level available. In 1968, Chevrolet introduced the Chevy II Nova; the top trim levels were now the Nova 400 and the Nova SS, but these cars carried the name Chevy II in the grille surround. In 1969, the Chevy II name was dropped completely in favor of Chevrolet Nova.

The Chevy II the crew at MetalWorks is building will be getting the full Pro Touring treatment as well as a long list of sheetmetal refinements. Dayton Eitner handled the bodywork, executing subtle modifications so seamlessly that it takes a keen eye and some time to notice exactly what’s been changed. Cleaning up the dash, cowl, and firewall of this second-gen Chevy II is a perfect example of less being more.

1967 Nova original dash and cowl with factory defrost and air vents pre-modification close-up
2. On top of the factory dash, the large defroster vents and a grille for the radio’s speaker will be eliminated.
1967 Nova cowl cutout process exposed inner dash structure sheet metal prep custom metalwork
3. Eitner removed the section of the dash with the vents and speaker grille. The oblong holes are attachment points for the stock dashpad.
1967 Nova cowl patch panel tack welded metal shaping in progress custom vent delete panel
4. A filler piece for the dashboard was fashioned from 20-gauge mild steel. It was cut to size and tack-welded in place.
1967 Nova cowl smoothing grinding welds metal finish work pro-touring custom bodywork
5. With the filler panel completely welded, a shrinking disc was used to remove any high spots.
1967 Nova smoothed cowl metal finished surface removed factory vents for modern clean look
6. After running the shrinking disc over the surface, the welds are practically invisible.
1967 Nova firewall and cowl mockup with AC system mount Vintage Air smoothed firewall fab
7. With the stock heater box and windshield wiper motor removed, the portion of the firewall that mounted those components was removed.
1967 Nova close-up welded patch panel firewall reinforcement shaved holes sheet metal work
8. For ease of installation and use of a bead roller to add accents, the replacement firewall was made in two pieces. Note the holes at the top of the first panel for plug welds.
1967 Nova fully fabricated and smoothed firewall bead rolled panel hot rod engine bay ready
9. The second piece of the new firewall fits flush with the surrounding sheetmetal and ties into the original master cylinder mounting point.
1967 Nova welding custom firewall bead rolled sheet metal panel hot rod build fabrication
10. To prevent warpage, Eitner made a series of widely spaced tack welds to hold the new firewall’s centersection in place. Note it also has holes for plug welds that will secure the panel to the cowl.
1967 Nova firewall smoothed with coilover front suspension and rack-and-pinion installed, showing clean engine bay layout
11. With the welds blended, the finished firewall is clean and simple. Made from 18-gauge steel, the revamped flat firewall is rigid and makes for a roomier engine compartment.
1967 Nova factory cowl vent before modification with original slotted grille and wiper post visible
12. Like most cars of the era, the Chevy II had vents in the cowl to supply outside air to the heater. Since they won’t be needed, they will be eliminated.
1967 Nova cowl vent cut out revealing fresh air intake cavity and exposed dash structure
13. The grille in the cowl was cut out, leaving the mounting point for the passenger side windshield wiper.
1967 Nova patch panel formed on English wheel beginning custom cowl vent delete process
14. An English wheel was used to contour the cowl patch panel to match the slope from the hood to the base of the windshield.
1967 Nova cowl panel shaping continues with English wheel forming compound curvature in raw steel
15. The English wheel was used again to make the patch panel’s second contour from one side of the cowl to the other.
1967 Nova patch panel matched to cardboard template ensuring correct contour and fitment
16. To eliminate guesswork, Eitner made a template to verify the patch panels fit properly.
1967 Nova custom cowl filler panel test-fit showing tight alignment and clean transition
17. Made from 20-gauge mild steel, the patch panel was cut slightly oversize to allow trimming for a precise fit.
1967 Nova filler panel marked for trimming using magnet block and fine line scribe
18. Using magnets as a “handle,” the replacement panel was held under the windshield blister and marked for trimming.
1967 Nova cowl patch flanged using shrinker-stretcher tool for refined edge profile
19. A shear was used to rough trim the filler panel to shape.
1967 Nova custom patch panel final sanded on belt sander preparing surface for install
20. For a precise fit, the final trimming of the filler panel was made with a belt sander. It’s best to take a little at a time than too much at once.
1967 Nova cowl patch tacked in place with TIG torch and scribe used for tight seam alignment
21. Again, widely spaced tack welds were made to prevent warping the new panel.
1967 Nova cowl panel fully tack welded with hammers on deck lid and roll cage visible inside
22. Using magnets around the edge, the cowl panel was tack-welded in place. Note the temporary welding rod handle to pull the panel up when necessary, as it’s not accessible from below.
1967 Nova cowl patch fully TIG welded and ground flush into windshield base channel
23. With the spaces between all the tacks welded solid, the edges were ground.
1967 Nova cowl panel smoothed using electric heat-shrinker tool and hammers for final shaping
24. Rather than use filler, Eitner used a stud gun to raise a low spot. The gun welds a stud to the surface.
1967 Nova cowl weld seams metal finished and pulled with slide hammer to correct low spots
25. A slide hammer is then attached to the stud and is used to up the low spot. Once the repair is made, the stud is ground off.
1967 Nova cowl completely smoothed and metal finished ready for primer and final blocking
26. Not only does the smoothed cowl look cleaner, but it also eliminates the possibility of moisture and debris getting inside the cowl that can cause corrosion.
1967 Nova RainGear wiper motor system mocked up with billet linkage and CNC mounts
27. A new Raingear wiper system, which mounts beneath the dashboard, was installed to replace the stock components.

MetalWorks Classic Auto Restoration
(541) 592-7894
metalworksclassics.com
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