I am trying to form my firewall. I have made the form according to the plans. However it looks like the forming process is going to be a little different than that of forming the ribs.

From what I have been able to tell from looking on mykitlog.com, for example, it looks like forming the flanges on the firewall is going to be a bit more of a free hand process. The basic shape is started using the form, but after that it seems like it is a combination of hammer, fluting pliers and hand seamer.

Can anyone provide any further details on the firewall forming process?

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Hello, Damon

It's been a while since I made my firewall... From what I can remember, it was pretty similar to the ribs. I was surprised at how easy it was to bend the steel.

There was a spot (bottom corners) where the crimps are quire pronounced, but that was the only thing out of the ordinary.

Good luck

The easy forming of the steel is what has me confused. With 6061-T6 I am used to seeing about 15 degrees of springback. With the steel it turned out to be about 3 degrees. This means with even no bevel added, I would  overbend several areas of the firewall if I just hammed all the way like I would with a beveled rib form.

I formed one out of titanium that someone here was nice enough to donate to my build. For that application I ended up drilling around the perimeter and folding up an inch or better at a time. Obviously for steel you can do it with fluting pliers, hammer, and block. I do still have the template made out of rosin paper if you would like it.

Thanks for the offer but I already have a plywood form made up. I think the plan will be to hammer the flanges up to about 60 degrees and work the rest of the way with  fluting pliers, hammer and block as you have done.

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