September 6, 2002

While the firewall looks flat in this picture, it has three distinct surface elevations. If we simply lay the firewall on a table and glass over it, the result would be a warped firewall.

We start with a large block of foam and recess the obvious areas in order to lay the firewall flat.

The lowest area of the firewall is the bottom section. It will have the deepest recess.

Once the firewall is in place, we tape all of the edges down flat.

A quick close up. All of the holes must be taped from behind if we ever expect to lift the part off the foam.

Here is the firewall reskined and curing. The large blocks you see are simply weights to ensure the edges are pressed firmly against the foam. Once cured, we will trim the part one last time before installation.

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