I've drilled out all of the spot welds using a spot weld cutter. I only punched the whole waythrough 3 or 4 times. Anyway, I've been using a small screwdriver and hammer to 'break' the welds where the cutter didn't get the whole weld, to try and pry open the top cover. Both sides and the front by the engine bay are completley broken loose. My problem is I can't get to the welds on the flat part below the windshield opening. I've gotten the ones right along the windshield opening, but there's no way to get a screwdriver down to the flat part right in front of them (toward the front of the car). I'm thinking the spot weld cutter should have been a little wider. Anyone have any ideas. I don't want to force it, as I'd like to try and reuse the cover. I'm really anxious to see what lies beneath.

Thanks guys,
Jeff

 

I bought the spot weld cutters and used them on 1/2 dozen spots than got a 3/8 bit and found it worked better. Only went through 4 or 5 times. Just have to be careful. Pop a slightly larger bit in a drill and redrill them out carefully and this should help.

 

Excellent idea! I'll give it a shot. Thanks!

 

You could also use an air chisel if you have one.

 

Same here I did better with the drill bit than a cutter.

 

I finally got the top off and it's not as bad as I was expecting. There are a few small rust holes here and there, but the metal appears pretty sound and the vent openings aren't completely rusted away.

That said,

What needs to be removed to remove the lower cowl? I thought about getting a new once piece (upper and lower) cowl and just welding that back in.
- Is it just attached at the same spot weld spots?
- It looks like I have to do something with the wiper arms?
- Are the vent somehow attached underneath the dash?

Maybe I'll just get a new top or reuse the one I took off??

Jeff

 

If not too bad may be easier to just put in some patch pieces.

 

Its more work but I'd suggest going with the 2 separate upper and lower pieces. The reasonis that its much easier to paint the inside while they are apart. Also, look around and find a section of stainless steel mesh and bond it inside the upper section right under the vents. This will keep 90% of the crap out of the cowl and help prevent blockages and rot in the future.

As for the removal of the wiper arms... I forget if they need to be removed or not. I had stripped out our car beforehand so they were already out. That said.. even with everything else removed from behind the dash its a pain in the a$$ getting to the wiper assembly!

 

The lower cowl panel mounts the heater box. There is a bracket on the outside rear corner of the heater plenum that connects to the underside of the cowl panel. There is a "donut" type gasket that connects/seals the heater plenum to the underside of the cowl panel.

The lower cowl panel also mounts the freash air box on the drivers side.

The WS wiper pivot points mount to the underside of the cowl panel.

I agree that if the damage isn't that bad to just repair with patch panels.

Re-use your original upper cowl panel (nothing fits better than OEM panels).

Prime/paint and seal the heck out of the lower cowl panel before you start reinstalling the outer cowl panel.... you're not going to want to do this job twice.

Dave