I have been thinking for a long while about the top edge of the firewall. The cowl cover must be removable, so it will fasten to the top of the firewall. The top edge must be something more than just the edge of the sheet metal. Yesterday, I viewed the Homemade Tools section of Hotrodders.com. Someone had modified a pair of vise grips to roll a sheet metal edge. That inspiration was what i needed! I copied the tool using a piece of push rod and a piece of 1/2 inch square tubing cut longitudinally. I marked four parallel guide lines 1/8 inch apart along the loose top of the bed rail and started mashing the vise grip tool along the four lines. The rolled edge came out with a larger diameter than did my test pieces, but it will suffice for my need.
I have given up the idea of using a bead roller to emboss a decorative image into the firewall. Instead, I'll use the front wall from the S10 bed which is embossed with seven rectangular shapes. I cut the top rail from the wall and will use the loose piece to reinforce the edge of the wall that I cut from the floor. The loose piece needs to bend slightly, arching about 3/4 inch in the center, to match the arch of the cowl cover, so I made a relief cut.
Cut a piece of 18 gauge for the firewall and bent the bottom to make the turn into the floor. I'll have to raise the piece about six inches to get it right. Took some time this weekend to sketch some patterns for beads in the flat panel for decoration and stiffness. Thought some Art Deco-style lines might fit with the time period I'm trying to mimic. Settled on one pattern and started drawing to scale.