How-to repair pinholed firewall

[4x4M38]

I'm still waiting on a call from one of our vendors to see if they can provide a portion of the firewall needed so I don't have to build one from scratch. However, given that this is a common ailment on the Jeeps with cowl battery boxes, thought I'd throw it out for discussion.

I have an early firewall, MC11481, so would prefer not replacing the whole thing, plus the only real damage is right here in this area. Other than extra Bubba holes which are fairly easy patches with a MIG, I have pinholed and paper thin sheet right down the raised area where the two left air cleaner bracket bolts are.



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My plan was to obtain a fairly small patch panel from a good tub. Failing that, fab up a repair panel. I am no expert in any sense of the word, so I approach this with reluctance. The difficulty is of course the stamped, or raised area.

1. Thought of trying to make a die from hardwood. Flat base, thin middle area with the desired raised area drilled out and radiused, and a flat, upper piece for the sheet to sit on. Using a hardwood dowel of the right diameter, hammer the area working down the piece. Using hardwood due to lack of heavy duty metal working tools. Drill holes and weld the bolts in place.

2. Cut out a flat piece of sheet the size of the needed repair. Cut out the raised area with extra metal for forming, form the raised area with a radiused edge to sit flat onto the sheet. Weld the two bolts to the front portion of the sheet. Drill the raised portion for the bolts, slip over the bolts and weld all around the edge to the flat sheet.

I can't imagine which one of these is the more difficult fix.

Ideas?
_________________
Brian
1950 M38
MC11481
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