OK guys finally got the cowl all done. What do you think? It was a pain. The biggest mistake I made was drilling all the way through on the spot welds. Now I have to figure out how to close those holes up properly. But overall I think it turned out nice....now on to the floor pans!!!!!
looks like a great job... I guess you know by now what a...spot weld cutter is... screw the top back on, then remove one screw at a time and weld that hole. after welding up the screw holes then get to the drilled ones...
It's all spot welded back... but what's the best way to filled these holes on the top near the windshield? I can't put anything under them to weld them shut. Will the windshield and trim cover them?
I started on the floor last night... wire wheeled everything and cut out the bad spots. I aquire 18 gauge sheet metal. Purchased some all metal for the small holes and some por 15. Any suggestions on getting this done guy...Besides beer and country music to make it go easier.
Nice job - with the inside coated properly now, you did it the way Ford should have done it to begin with
Did you topcoat that Por15? If the cowl is still open it will be exposed to sunlight/uv rays; IIRC Por states their product should be top coated if exposed to UV.
I used a spot weld cutter from Harbor Freight, when I removed my cowl top which did not cut all the way through but I still had issues with how thin the metal had become from corrosion - when I get back to my car in the spring, I am going to use a automotive panel adhesive to rejoin the cowl top to the firewall
I closed the cowl up. The car is garage kept. I don't think the little sun that gets in through the vents will be that bad
I've made a lot of progress on the floor. I cut out all the bad spots (2) on the driver side. All metal in the little holes and por 15 the entire floor. The two bad spots were replaced with 16 gauge galvanized sheet metal.
The best way to fix this and NOT burn the car to the ground would be to remove the dash and heater box. It's not as hard as you'd think, and it'll do a much nicer job when you're done. I flattened a piece of 1/2" copper pipe and clamped it under the sheetmetal and filled my holes in that way. It took some grinding, but it worked out in the end.
