cowl panel replacement - Hot Rod Forum : Hotrodders Bulletin Board -- Hot Rod Forum

Register FAQ Search Today's Posts Unanswered Posts Auto Escrow Insurance Auto Loans
Hot Rod Forum : Hotrodders Bulletin Board > Tech Help> Body - Exterior
User Name
lost password?   |   register now

LinkBack Thread Tools
  #1 (permalink)  
Old 01-02-2009, 11:29 PM

Last journal entry: Cowl Panel RUST!
Last photo:
Join Date: Nov 2003
Location: Santa Monica
Age: 32
Posts: 91
Wiki Edits: 0

Thanks: 0
Thanked 0 Times in 0 Posts
cowl panel replacement

i was wondering how hard is it to replace the cowl panel on a 67 mustang, i just noticed that my car is rusting from the cowl panel which is common on these mustangs.

theres a link to my project journal that shows the rust hole i found a week ago.

i was going to have a body shop replace this area like my radiator support but found that they want a #### load of cash for a project like that.

is this a project that someone that has never welded before can handle or should i just give up and find a new home for the stang?

Reply With Quote Quick reply to this message
Sponsored Links
  #2 (permalink)  
Old 01-03-2009, 07:10 AM
wildthing's Avatar
Registered User

Last journal entry: 95 % done
Last photo:
Join Date: Jun 2007
Location: chambersburg, pa.
Posts: 223
Wiki Edits: 0

Thanks: 0
Thanked 0 Times in 0 Posts
that is not a project a non welder can do. i have a 68 cougar and my first car the cowl area was shot and rusted the floor panels. i sent what was left of that car to can go back to the beginning of my journal to see what it looks like.
first the cowl is connected together by a couple hundred spot welds that need to be drilled or cut out. and the more you dig the more damage you will most likely find. the lower cowl will probably need replaced and that ties to the fire wall and side cowl panels. plus all your dash ties into this area. it is a huge job........
Reply With Quote Quick reply to this message
  #3 (permalink)  
Old 01-03-2009, 07:52 AM
Registered User
Last photo:
Join Date: Jan 2008
Location: Kemah TX
Posts: 425
Wiki Edits: 0

Thanks: 0
Thanked 0 Times in 0 Posts
If under the WS corners is all the rust you have the job is not that big of a deal. Take your time and learn how to weld sheetmetal before you start welding on the car. Remember heat shrinks steetmetal so take your time welding the new panels in to keep the warping to a mininum.
Reply With Quote Quick reply to this message
  #4 (permalink)  
Old 01-04-2009, 10:21 AM
Registered User
Last wiki edit: First paint job Last photo:
Join Date: Aug 2008
Location: NorCal Bay Area
Posts: 94
Wiki Edits: 6

Thanks: 0
Thanked 0 Times in 0 Posts
Tin Can method

Lots of pictures of the repair on our web page:

The 66 had been parked in a container since 1978 at the construction site. Lucky for us it had not been exposed to the elements for the last 30 years.
We ran a garden hose into the cowl and made sure it drained out the fenders and checked for leaks inside the car but found NO water. We have a rare Mustang that has not rotted out the cowl or tophats.
We decided to use the "Tin Can" Method to check them out by cutting the end caps and bending them up.
The cuts were done with a 4 1/2 angle grinder and a 1/16 inch thick cutting wheel. To finish some cuts, a hacksaw blade was used.
We used Eastwood Rust Encapsilator on all the metal to stop rust from forming. All of the metal seams and top hats were coated with seam sealer (Eastwood). I should have used black Rust Encapsilator to eliminate having to paint it.. lesson learned.
After coatings were applied, we MIG welded the cuts back together, ground down the welds. We then applied paint and seam seal on top of the welds. The area is covered by the fenders so it will not be seen.
It took 1 weekend to complete.
If the 66 had needed new top hats installed, we were going to extend the cuts towards the center of the car and follow the procedure from this link:
Luckily, we did not have to!!!
Reply With Quote Quick reply to this message

Recent Body - Exterior posts with photos

Quick Reply

Register Now

In order to be able to post messages on the Hot Rod Forum : Hotrodders Bulletin Board forums, you must first register.
Please enter your desired user name (usually not your first and last name), your email address and other required details in the form below.
User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:
Please select your insurance company (Optional)


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
Welding a panel in place Quarter Flash Body - Exterior 6 03-22-2007 02:56 AM
replacement cowl modas Body - Exterior 0 02-15-2006 09:52 AM
metalshaping and panel replacement '40 Willys roof Randy Ferguson Body - Exterior 18 11-26-2005 09:00 PM
67' Mustang fastback cowl grille replacement Pencilneck314 Body - Exterior 0 01-16-2004 08:10 PM

All times are GMT -6. The time now is 08:14 AM.

Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0 PL2
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2017 DragonByte Technologies Ltd.
Copyright 1999 - 2012. All Rights Reserved.