'HOLEY' COWL

I must prefix this by saying cowl replacement is not fun. My driver side cowl was horrifically rotten and was in need of new metal. I decided to get only the partial replacement panel as the rust hadn't traveled more than 18" over from the edge of the drivers side cowl. Take a look:


Yummy...

I used several tools to get to this point. Removing the spot welds was a pain as anyone can tell you. I believe I removed 35 of them to get to this point. The real trouble is when you use a chisel or pry tool to drive between the upper and lower cowl. It's almost impossible not to distort the flanges in the upper cowl.
I'll do my best to flatten them out afterward but it's a good thing that most of these areas will be permanently covered.



Zinc weld primer was used around the areas I am going to weld

Por-15 layered onto the bottom and top of the new cowl. No way will I ever want this thing rusting again! I also added some seam sealer to any joint I felt might pose a leak problem.

Here we have the lower cowl installed. Welds were ground smooth and a good layer of Por-15 was put over the new and old cowl. I had to use a stick and a brush to try and reach as far over to the other side as possible. I couldn't quite reach the passenger cowl but that looks to be in great shape. If the opportunity makes itself available and I am able to access the passenger side I will repeat the painting process....hopefully I won't have to.