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<\/a>1. Examining Passenger Cowl Rust at A-Pillar<\/p><\/div>\n
<\/a>2. Measuring Passenger Wheel Housing Rust at A-Pillar<\/p><\/div>\n
<\/a>3. Cowl after Cutting Old Patch<\/p><\/div>\n
Forming Cowl Patches<\/strong> 4. Forming Cowl Patch by Hand<\/p><\/div>\n 5. Checking Cowl Patch Curvature<\/p><\/div>\n 6. Forming Sharp Bend on Cowl Patch<\/p><\/div>\n 7. Double Checking Cowl Patch Curvature<\/p><\/div>\n 8. Super Magnets Holding Cowl Patch in Place<\/p><\/div>\n 9. Passenger Wheel Housing Trimmed and Hood Mount Removed<\/p><\/div>\n Fitting the Cowl Patches<\/strong> 10. Replacing Rusted-Off Section of Firewall<\/p><\/div>\n 11. Passenger Cowl Patch Ready to Weld<\/p><\/div>\n 12. Passenger Side Cowl Patch Tack Welds<\/p><\/div>\n 13. Driver Side Cowl Patch Fitment Check<\/p><\/div>\n Welding and Finishing the Cowl Patches<\/strong> 14. Passenger Side Cowl Patch Welded<\/p><\/div>\n 15. Passenger Side Cowl Patch Finished<\/p><\/div>\n Passenger Side Wheel Housing<\/strong> 16. Passenger Side Wheel Housing Patch Tack Welds<\/p><\/div>\n 17. Rusted Section of Cowl and Firewall<\/p><\/div>\n 18. Passenger Side Cowl and Wheel Housing Finished<\/p><\/div>\n Driver’s Side<\/strong> 19. Driver Side Cowl Patch Ready to Weld<\/p><\/div>\n 20. Driver Side Cowl Patch Almost Finished<\/p><\/div>\n 21. Driver Side Cowl Patch Finished<\/p><\/div>\n Fixing Rusted Cowl\/Firewall Section<\/strong>
\nI selected some dies from my Harbor Freight metal bender and shaped some 18 ga metal for the curved section as shown in Figure 4. A little tougher than I thought because it’s a bit of a compound curve (bent in both directions) but I was able to get a pretty close match. See Figure 5. In Figure 6, I’m adding the right-angle bend and checking fit in Figures 7-8. Figure 9 simply shows all of the metal I removed before proceeding. The hood mount was in the way and had to be temporarily removed.<\/p>\n<\/a><\/a><\/a><\/a><\/a><\/a>
\nFigure 10 shows a small patch welded in to replace a rusted extension of the firewall. Figures 11-12 show how effective small, neodymium super magnets can be for holding a patch in place for tack welding. Just don’t weld too close to them unless you like to see flying molten metal. Figure 13 shows a similar patch being readied for the driver’s side.<\/p>\n<\/a><\/a><\/a><\/a>
\nFigures 14-15 show the passenger side cowl patch after welding and finishing.<\/p>\n<\/a><\/a>
\nFigures 16 and 17 show the wheel housing patch after being tack welded into place. The circled section in Figure 17 shows a spot where the cowl and firewall rusted clear through the firewall. This section is discussed again below. Figure 18 shows the completed passenger side work.<\/p>\n<\/a><\/a><\/a>
\nFigures 19-21 show similar cowl work performed on the driver’s side.<\/p>\n<\/a><\/a><\/a>
\nReturning to the circled section in Figure 17, I carefully cut a large section of the firewall which gave me an opening big enough to replace a small section of the lip of the cowl. After repairing the cowl lip, I welded a patch into the firewall as shown in Figure 22. I love those super magnets. And finally, in Figure 23, you can hardly tell the cowl and firewall had been repaired.<\/p>\n