'66 cowl restoration

[zm830101]

well, got started on the cowl restoration on my coupe. been a long time coming and i am finally getting around to it. i was hoping that it would be a simple patch of the lower panels but it looks like that is no longer an option. while grinding on the spot welds i noticed this.

it looks like at some point my aunt, who bought the car new and gave it to me (i have owned it for the last 15 years), must have had somebody attempt to repair the cowl during the time she owned it. to the credit of the hack who did this, he was a bondo MASTER. i didn't even know this was here he hid it so well.

so, can you buy just the top of the tank anywhere, or do you have to buy the entire welded assembly? i would rather not buy a fully welded assembly just to have to cut it open and seal the inside. also, i think i remember there being a discussion on here involving the pass threw for the wipers being different from 65 and 66 and there being some issue with the fitment of the repro cowls. can anybody offer their insight into this?

 

[C0V3R]

it doesnt look that bad - you could weld it back up if you wanted to and are handy with a mig.

just stich it up with small welds to keep it from warping too much.

 

[chris66dad]

If your cowl does not leak, here is what we did:
Cowl Repair

If your tophats leak water onto the floor and you need to replace them here is another option instead of a full blown removal of the top:
Boyd's Mustang: Cowl repair

Just a couple of options to think about that might work for you to save time and money.

Good Luck and BE Safe
Ron

 

[zm830101]

well, got the top tank off. i have to say, i was expecting the worst based on how badly the cowl leaked. i was pleasantly surprised at how much good sheet metal was still there.

surprisingly, the worst of the rust wasn't around the cowl hats at all but rather right below the a pillars.

driver's side

passenger's side

i decided i am gonna try to salvage the top tank. i'll get more pics up as i get along

 

[chromedog]

your lower looks about like mine did, difference being the car had sat under a pine tree for the last 8 years, the vents were full of pine straw, and the top was TRASH!!! my only option was to find a good replacement section and fab it in. i was lucky enough to find one in excellent condition via the internet parts locator service.it cost me 280.00 by the time i had it shipped from cali. to ohio, but what do you do in this situation?

 

[lauras70mach1]

My '70 was rusted int he same spot. There are four layers there all sandwiched together. By the time I was done I had replaced them all.

 

[68mustangkb]

I have a 1968 mustang that had the same issue. But the vent holes were eat about 2" away from vent. I just cut the vents out and welded in flat metal and formed it the run the water off. I tried to post pictures but it did not let me. I need to resize them. I will post them later

 

[zm830101]

well, i have been a little busy lately but i have some more photos to post up.

got the driver's side cut out

and the passenger side

had to fabricate a little patch panel for the driver's side

and then got the cowls welded in.

a view of both sides

got the top tank stitched back up
passenger side

diver's side

got the top tank all ginded up and i am actually very pleased with how well it turned out. a skim coat of bodo and it will be perfect

 

[NasaGT]

Nice job, looks good!

 

[chris66dad]

Nice job and thanks for a great write up.
Welcome to the "I-Got-R-Done" cowl club. Membership has its privileges, no wet feet or carpet!
Good Luck and BE Safe
Ron

 

[zm830101]

it's all through now but the cryin' ... well, hopefully no cryin' but you know what i mean