Classic Mustangs (Tech)Technical discussions about the Mustangs of yester-year.
Welcome to Mustang Forums!
Welcome to Mustang Forums.
You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, at no cost, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!
So as I'm taking out my floor plan to replace, I also cleaned out everything underneath the dash. A lot of it looks like surface rust and i'm hoping a cowl patch repair kit will do, but the cowl vents DO look kinda bad.
Is this acceptable to patch and repair? Or do I need to replace it? I'm hoping it's not the latter cause I hear the 154+ spot welds are a P.I.T.A. to go through.....
This ad is not displayed to registered or logged-in members. Register your free account today and become a member on Mustang Forums!
This is a ridiculous thread that nobody is answering because we all know the answer. I've already gone so far on this first project car and so much has already been invested, no sense in taking shortcuts. Everything is clear under the dash, the fenders are out, and my engine bay is empty. I need to put in the new floors, install my rear suspension, turn the car around and replace the cowl. Maybe I can get away with just replacing the partial cowl panels themselves and not the entire lower section, but this needs to be done..........
Maybe nobody has responded yet because of the time of year, and it's only been a day. Or, perhaps it's the pictures. I don't really see a problem other than surface rust. Do you have pictures of any rust holes? Don't really see a big problem here?
Sorry for the crankiness. No, there aren't any holes. The rust isn't as bad as my floor pans, but the layers look pretty thick. I didn't pour any water down, but I took some more photos. Is the dark corner seam the water leakage you're talking about? Hence the cottage cheese floor pan?
I tried taking pictures inside the cowl with my camera and cell phone, but couldn't get a clean result. And yes...i was talking about the plastic repair piece that you simply adhere to the cowl...
I have yet to hear from anyone who has had anything other than temporary success with the plastic hats, myself included. To be honest, your cowl is one of the better ones I've seen in a while. If it's not leaking, I'd try cleaning what surface rust you can and use a rust encapsulator by reaching through the vents and pouring or spraying it through the grille.
Really I can't tell from those pictures and I don't see how anyone could. Pouring water down will tell you if it's leaking and I'm sure it is if you have rusted floor pans. How bad is the rust? You'll have to dig into it to be sure. If you don't want to take any shortcuts, and if there is water leaking, you'll have to open up the cowl and tackle it from there. Those corners look iffy.
Installing the plastic covers is a short cut and I think looks like crap.
You could cut the hats out with a dremel or something, then clean the cowl area out real well, use some phosphoric acid to kill the rust, paint the area, then put the plastic hats in with plenty of silicone.
I did the water test today and got the same results for both sides. The water went straight through the drain hole and down onto the ground...which is exactly what it's suppose to do, right? I may have cleaned it out a bit last year when i restored the front engine bay, so i'm assuming when it was clogged for 40+ years it rusted the floor some.
My normal UPS driver was in the neighborhood today and he stopped by to see the progress. He said my cowl vents actually don't look that bad and a wire brush followed by some rust treatment will do. He also said I'm 1 step away (removing window and wiper) from having everything clear to replace the cowl and not worry about it ever again. Guess i'm at the crossroads in this case?
It could have been one of the glass gaskets leaking that let water in the car that rusted out the floor pan.The cowl is the first thing that gets blamed but there is other ways like the leather gaskets on the wiper arm shaft holes that rotted away 20 years ago.
You'll have to decide what to do about this at this point. You do not want to have an issue with the cowl leaking after the car is back together and finished. As you said, now it's not leaky, but be sure you're not one rainy season away from the cowl letting loose.
If it was me i would cut the corners off the cowl por15 the whole inside and weld it back on.If you are going to use a aftermarket heat and air some don't use the cowl so you could shave the cowl vent off it.
This forum is owned and operated by Internet Brands, Inc., a Delaware
corporation. It is not authorized or endorsed by the Ford Motor Company and is not affiliated with the Ford
Motor Company or its related companies in any way. Ford® is a registered trademark of the Ford Motor