Just purchased a 68 and it has the nasty rusted out cowl problem.

A few months back I read a post about cowl repair and someone had posted a picture of the way they had fixed their cowl. Instead of drilling out the hundreds of spot welds, they cut through the cowl top on both sides and then rewelded and repaired the cut after the cowl was fixed. I've tried searching and haven't been able to find that post. Can anyone direct me to that post?

Thanks,
Jeff

 

Jeff,
if your cowl is rusted as bad as im getting a mental picture of you might just want to go ahead and replace that whole area with a new cowl,. the time vs amount of work spent for the results might not pan out to what you want.

http://www.parts123.com/parts123/yb....Z5Z5Z50000016e

 

Thanks for the input. Actually it's not that bad as far as I can tell. It does leak into the interior though. I was hoping to get by with just the repair panels ( a lot cheaper), but I didn't want to do all that spot weld drilling. There is a guy on here that cut the tops section of the cowl on each side to do the repair. I just want to see that post again to see how he made out. I guess I'll keep searching.

Thanks,
Jeff

 

you could flush it out and never have a leak again. If you are into the restomod look.

 

I'm curious, how do you flush it out? My cowl seems ok right now, but I want to make sure it won't rust. Thanks!

 

weld sheet metal over the vents. Here is a bad pic taken right after I welded mine shut.

[IMG]local://upfiles/64293/A5D44AE3B7E44A5D940B640C53CDAD05.jpg[/IMG]

 

I also am going to weld it shut but i was wondering if i should fix the problem first then weld it shut or just leave the rust and weld it shut?

 

depends on how bad it is and how well you will sleep at knight knowing it is rusted out and you did nothing about it other than cover it up. I would probly fix it then weld it over. You can cut out the vent louvers and fix it from the top then make a panel to fill in the hole.

 

im not sure how rusted it is but say it was to be really rusted, what the average cost to replace/ fix or does it depend on how much damage the rust has caused?

 

Hey Partner,

Having gone the spot weld removal route, I would say this is the best and most effective route. However, I do understand not wanting to remove the windshield to do this. That being the case, Mustang Monthly covered this repair in one of their articles several years ago by cutting into the area (after removal of the front fenders) located near the edgeof the cowl. Check theirsite for links. If not successful, let me know, asI have every mag since December 1984. I'll have to do some digging.
good luck!