I have a '65 SS where the previous owner installed a carberator with a manual choke. In order to get the choke cable under the dash, he drilled an irregular shhape hole in the firewall that you could pass a quarter through! Naturally this hole lets in lots of water when it rains. Does anyone have any good tips for repairing or sealing up the hole - I still plan on using the manual choke.

best place I have found all kinds of things to seal holes is at lowes in the specialty fasteners drawers, plastic push in stuff and or caps for holes, etc..etc.. Home depot might be good also. If the plug is a little loose I've used seam sealer to hold it in place.

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72 Chevelle and a 70 Chevelle with a crushed roof
ACES # 4051 MCC # 448
TC # 1549 81/70 Cruisers

Check the electrical section at HD, or a contractor level electrical parts distributor. There are all kinds of snap-in plugs, or water-tight plugs available to cap off (per code) unused or mistakenly knocked out holes in electrical boxes. They are sized for standard electrical conduit fitting sizes, from 1/2" up through 3". You may need to enlarge the hole in your firewall to fit the next size up. Or you could scrounge the boneyard for a rubber grommet on a wreck that's capping off an unused accessory / wiring harness hole.

I use butel (sp) tape. The stuff that comes on a roll to hold your front and rear windows in. The stuff is handy when assembling your car too!