I've done so many cowl repairs . . .

Moderator: FORDification

PetesPonies
New Member
New Member
Posts: 121
Joined: Wed Jan 23, 2008 10:37 am

I've done so many cowl repairs . . .

Postby PetesPonies » Mon Mar 20, 2017 9:22 am

on Mustangs, I was just wondering how many of you here have tackled it on your truck? This cab came from NC, but it was still plenty rusty. I replaced floor panels, rear cab corners, one cab support and fixed a ton of dents. But from leaves and such sitting in the cowl, it was very pitted to the point where lots of pinholes were going through to the inside. So . . off it came. Holes welded, coated with two coats of master Series silver, then sprayed a sealer. Then the tedious job of welding it back on. I believe I can get the welding done today on the cowl and then seal the welds. I'll post more pics.
Image
Image
Image
Image
Pete's Ponies
Mustang RUSToration & Performance

User avatar
sargentrs
100% FORDified!
100% FORDified!
Posts: 7991
Joined: Fri Jun 22, 2007 9:30 am
Location: Georgia, Jasper

Re: I've done so many cowl repairs . . .

Postby sargentrs » Mon Mar 20, 2017 11:03 am

Great work and thanks for showing us how you did it! :thup:
Randy
1970 F100 Sport Custom Limited LWB, 302cid, 3 on the tree. NO A/C, NO P/S, NO P/B. Currently in 1000 pcs while rebuilding. Project thread: viewtopic.php?f=22&t=59995 Plan: 351w, C4, LSD, pwr front disc, p/s, a/c, bucket seats, new interior and paint.
1964 Ford Fairlane 500. 289/Cruise-O-Matic, A/C, P/S.

PetesPonies
New Member
New Member
Posts: 121
Joined: Wed Jan 23, 2008 10:37 am

Re: I've done so many cowl repairs . . .

Postby PetesPonies » Mon Mar 20, 2017 12:45 pm

More pics. First two are bare welds after grinding.The last pic shows the weld sealed with Master Series. As far as how I did it . . it would have been much less welding if I separated the cowl at the windshield pinch weld. But, there are 44 spot welds there ( about 115 on a Mustang all around it ). That would have been a chore in itself, I know this. So for me, I chose to do a long butt weld. I can do them well, so it was just a preference. If your welding skills aren't as good, then drilling out the pinch weld would save you a lot of welding.
Image
Image
Image
Pete's Ponies

Mustang RUSToration & Performance

PetesPonies
New Member
New Member
Posts: 121
Joined: Wed Jan 23, 2008 10:37 am

Re: I've done so many cowl repairs . . .

Postby PetesPonies » Mon Mar 20, 2017 6:52 pm

Here's a last photo as to where the cowl was welded across the front. I made my cut right through the holes for the cowl seal clips. This also gave me the opportunity to move two holes slightly, so the aftermarket cowl seal can clip in place. Any of you who have bought a new cowl seal know the problem I speak about. And this weld will be completely hidden by the seal, if welding here scares you :) Drill the welds at the windshield, cut/weld the front as I did and the only weld you will see will be the short welds on both ends. That's as easy as I can make it for you :)
Image
Pete's Ponies

Mustang RUSToration & Performance

User avatar
Madman
100% FORDified!
100% FORDified!
Posts: 1643
Joined: Thu Oct 13, 2011 9:39 am
Location: Windsor, CO
Contact:

Re: I've done so many cowl repairs . . .

Postby Madman » Mon Mar 20, 2017 9:02 pm

You do solid body work my friend!
""Never shoot a large caliber man with a small caliber bullet."

1970 F250 4x4
1948 Willys CJ2A w/ Ford Flathead V-8
2007 Shelby GT-500 (Sadly has moved on...:(....)
2010 F150 FX4
2014 Raptor SVT

PetesPonies
New Member
New Member
Posts: 121
Joined: Wed Jan 23, 2008 10:37 am

Re: I've done so many cowl repairs . . .

Postby PetesPonies » Mon Mar 20, 2017 9:30 pm

Thanks, I do restoration work on cars, mostly Mustangs.I also taught auto and engineering in a high school. S I have taught many to do some of this and I show it here hoping some will take it on. I haven't seen or heard much about the cowls on these trucks, at least on line. There has to be others out there , , are you just avoiding it? I have a '71 that is rust free, a true survivor. His name is Gumby. But I also have a '69, that I put a 428/4 speed in. The cab from that truck is shot, and I mean shot. Terrible cowl rust, really bad. So I bought this cab ( the one pictured ) to replace the cab on my '69. I bought it long ago, when I lived in Maryland. I have had it probably 10-12 years I guess. I'm finally completing the body work and hope to get it painted this spring. I'm doing the '69 ground up, so I will be sitting the painted cab on a painted frame and go from there. So . . who else has terrible cowl rust?
Pete's Ponies

Mustang RUSToration & Performance

User avatar
67mann
Blue Oval Guru
Blue Oval Guru
Posts: 1417
Joined: Thu Feb 07, 2008 7:19 am
Location: NY..Mt.Morris 3rdgen. homestead

Re: I've done so many cowl repairs . . .

Postby 67mann » Tue Mar 21, 2017 5:34 am

PetesPonies wrote: So . . who else has terrible cowl rust?


I would probably venture out and say :hmm: most of us :D You Sir did a beautiful job :clap: (got me thinking) but, that's a lot of work and past the skill level of a lot of people that are just hobbyist or wkend warriors. North/South, rainy to dry states would make the big difference in how bad or terrible the condition would be :2cents:
I've had enough and I'm not alone
http://s267.photobucket.com/albums/ii304/67mann/

PetesPonies
New Member
New Member
Posts: 121
Joined: Wed Jan 23, 2008 10:37 am

Re: I've done so many cowl repairs . . .

Postby PetesPonies » Tue Mar 21, 2017 8:59 am

Absolutely and why I thought I was getting a decent one from NC, at least not too snowy, not the salt like we had in Maryland.
Pete's Ponies

Mustang RUSToration & Performance

Lone Ranger
Preferred User
Preferred User
Posts: 274
Joined: Tue Jun 21, 2016 2:27 pm
Location: Northern Michigan

Re: I've done so many cowl repairs . . .

Postby Lone Ranger » Thu Mar 23, 2017 1:27 pm

That turned out terrific! Great job. I had thought about just trying to oil my cowl or just spray some kind of film in there to help protect it a bit longer. I would be pretty nervous cutting such a big chunk out of my cab and trying to make it look good.
1972 f100 4x4 4 inch lift with dump box kit-sold
1969 f250 4x4 highboy in progress.
viewtopic.php?f=22&t=85251
Kyle

PetesPonies
New Member
New Member
Posts: 121
Joined: Wed Jan 23, 2008 10:37 am

Re: I've done so many cowl repairs . . .

Postby PetesPonies » Thu Mar 23, 2017 4:29 pm

Piece of cake. Like I said, if you follow my lead, drill out at the windshield to avoid the long butt weld, then the only part that will be seen are the ends. Here's mine after epoxy.
Image
Image
Pete's Ponies

Mustang RUSToration & Performance

User avatar
Madman
100% FORDified!
100% FORDified!
Posts: 1643
Joined: Thu Oct 13, 2011 9:39 am
Location: Windsor, CO
Contact:

Re: I've done so many cowl repairs . . .

Postby Madman » Thu Mar 23, 2017 6:50 pm

PetesPonies wrote:Thanks, I do restoration work on cars, mostly Mustangs.I also taught auto and engineering in a high school. S I have taught many to do some of this and I show it here hoping some will take it on. I haven't seen or heard much about the cowls on these trucks, at least on line. There has to be others out there , , are you just avoiding it? I have a '71 that is rust free, a true survivor. His name is Gumby. But I also have a '69, that I put a 428/4 speed in. The cab from that truck is shot, and I mean shot. Terrible cowl rust, really bad. So I bought this cab ( the one pictured ) to replace the cab on my '69. I bought it long ago, when I lived in Maryland. I have had it probably 10-12 years I guess. I'm finally completing the body work and hope to get it painted this spring. I'm doing the '69 ground up, so I will be sitting the painted cab on a painted frame and go from there. So . . who else has terrible cowl rust?


I'm in Colorado and the truck is from Nevada, so no real rust issues on my rig, only the front fenders. Reason I bought the truck because the cab was damned solid. I restored Mustangs with my da in the 80-90s, and I know the cowls area a cast iron bitch.
""Never shoot a large caliber man with a small caliber bullet."

1970 F250 4x4
1948 Willys CJ2A w/ Ford Flathead V-8
2007 Shelby GT-500 (Sadly has moved on...:(....)
2010 F150 FX4
2014 Raptor SVT


Return to “Body & Paint”

Who is online

Users browsing this forum: No registered users