Cowl Repair

Discussion in 'General Maverick/Comet' started by Tannersg1, Sep 25, 2020.

  1. Tannersg1

    Tannersg1 Member

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    Time to put it back together...
     

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  2. mojo

    mojo "Everett"- Senior Citizen

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    How you plan to affix cowl top half? I assume some sort of panel bond -- to keep the beautiful from destroying paint work. Very nice work!
     
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  3. Tannersg1

    Tannersg1 Member

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    Just going to carefully spot weld it back on. Sand down the spot weld areas, spray them with some weld thru primer and hope for the best. Thanks for the compliment
     
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  4. stoney

    stoney Member

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    I’m putting floor pans in mine, but I gotta do the cowl next, I have water dripping in odd spots. What is the correct procedures in removing the cowl, where should I start?
     
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  5. stumanchu

    stumanchu Stuart

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    I think the method used in the pic requires the entire dash removed, and the windshield. There are other methods to take care of cowl leaks depending on the severity of your rust, which do not require as much disassembly. If you are up to the task of what you see in that pic, far be it from me to be any kind of naysayer.......I just cringe at the thought of well meaning peeps that tear their car apart that far to discover they are over their head. Soooo....start by using the search function and read as much as you can find. Get a good look at what is really leaking, and decide on a path that you can take that you are certain to finish. And keep asking questions. Dont mind me too much, I just really want you to be successful. Dont quickly rule out closing off the cowl grills.....that would be my first choice according to my metal melting skills, lol.
     
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  6. 71gold

    71gold Frank Cooper Supporting Member

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    where would these be? is it an A/C car?
    what shape is the windshield gasket in (broken/cracked/ pieces missing)?
    pour water just in the cowl, try not to get any on the windshield, if still leaking...
    pull the heater box . then you can reach up inside the cowl and feel for the holes.
    I bought a Mav once (cheap) that when you poured water in the cowl it would drip in the pass floor board. I pulled the heater box and found it and the cowl full of pine straw and leaves. the water was wicking over the tophat into the heater box. once cleaned out, no more leak.
    hope your fix is as simple.
     
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  7. Tannersg1

    Tannersg1 Member

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    I'm totally redoing my car so the windshield and dash were both removed. Either way the windshield and dash have to come out. Some have repaired the cowl without doing so . And they have also done so without removing the cowl cover. They just cut an area out fix what's needed and weld it back together. Honestly I put way to much work into mine but now I know its done right. Any questions feel free to ask.
     
  8. stoney

    stoney Member

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    I found sources of leak, firewall in the corner, bottom of hat in cowl 20201020_150150.jpg 20201020_150022.jpg 20201020_150028.jpg
     
  9. stoney

    stoney Member

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  10. stumanchu

    stumanchu Stuart

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    My cowl area was not rusted through anywhere, but was full of crud, and the hats had some rust. I thoroughly vacuumed, flushed as a piece of wire was used to keep the drain clear, washed, dried, and coated with POR 15, all through the vent hole under the dash. I also never planned to invest a lot of money into my car, so it didnt need to be perfect. Although my cowl does not leak, my car is not driven in the rain. Your problems are a bit more serious. I have seen pictures of members removing a fender and cutting into the cowl from the end, make repairs, and close it up using the fender to hide entry wounds. The question would be can you address your problems to your satisfaction through a limited entry, or is the full blown cowl removal what it will take to get where you want to be. It is amazing what can be done with POR 15 and fiberglass strips. I deem full cowl disassembly and repair to be more than I want to attempt.....and if I ever buy another Ford with the same type of cowl construction, I will hopefully know what to look for to avoid being stuck with a repair I cant handle well. I wish you success in whatever route you choose.
     
  11. Fastkarz

    Fastkarz Member

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  12. stoney

    stoney Member

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    The more you look, the truth comes to light
     

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