65 Satellite and I am looking at my upper cowl issue. It has rust through in the window channel in certain areas Rust through on both sides of the windshield channel. Also, where it attaches to the fenders plus (Pictures attached)the underside cowl metal just behind the dash has rust through in areas.
I am debating pulling the whole thing off to do a bench repair, as this is my first car I assume that is a huge job and I am not a patch panel master just learning. Of course would love the whole replacement piece that has not been easy to come by.
I have noticed there appears to be three layers of metal in the window channel I have tried to show it in one of the pictures, so if I do pull out the cowl would it be worth my while to drill through the first layer with the spotweld and try to salvage the other layers or would I just drill right through and when reattaching use a piece of copper on the backside and spot weld all the pieces back together ?
If anyone has attempted this procedure would love to hear and if you have any pictures would love to see them......
"I am debating pulling the whole thing off to do a bench repair,"
that's really the only way to do this repair, you need to see what's left under there.
"would it be worth my while to drill through the first layer with the spotweld and try to salvage the other layers"
yes for 2 reasons, re-aligning the panels 1 layer at a time and the inner panels will likely have other spot welds not aligned to the outer panel. Try to save everything that you can for patterns.
remove one layer at a time,using a spot weld drill,hammer and chisel...starting with the cowl piece.I'd cut it about an inch before the wiper and remove that section...remove it in one piece, if possible....make a new piece,buy a new piece.or have one made.its not a hard piece to make,I would think since this is a common place for rot you can find the whole replacement piece,you may even be able to locate a good used piece .use drill screws to fit the section or whole piece back on then go on to the next layer, working your way in...replace every layer as you come to it and attach with screws ...the screw holes will align the pieces in exactly the same spot every time.making the pieces will get easier the deeper you go on the inner structure since they are not seen just make sure you prime (epoxy prime) both sides before welding them in or it'll rust out again very quickly.Sorry I dont have a lot of pictures to show you but mabee these will help...drill screws and one layer at a time are the key to a good accurate job.... IMPORTANT!! assemble the fender to see how well the "cowl to fender gap is before welding the cowl piece on and use the windshield trim to make sure the curve is right before welding the cowl on also.But make up your mind to see it through to the end before starting.its not that hard and you'll have plenty of help on this end.first try to locate a patch panel ,I'd google the year and make of the car then "patch panels" or find a mopar forum to locate the piece... making your own should be a last resort,but it can be done,its only metal...You can pound it,bend it stretch it shrink it,weld it or glue it but enjoy it and you'll be way ahead ....If its more like work than fun I'd have a pro do it.
My 65 coronet convertible was in nearly the same shape. Kramer makes a patch panel for that. Not the nicest reproduction quality but it beats nothing. You are going to find that the lower cowl below that is trashed as well. Kramer is the only place I know of the makes a reproduction lower cowl for the drivers side. Again, poor quality but it will work. You will have to remove the whole upper cowl to install it though. Just drill out the spot welds and you can get it off without a lot of fanfare. Plus you can blast the backside of the upper cowl while it's off and epoxy primer it. It isn't as tough as you think but I had a big problem with the pitted metal when I tried to weld the upper cowl back on. The window channel burned a lot of holes that I had to plug. It warped the cowl in localized spots.
You may find a peice at a boneyard like Desert Vally but you will pay through the nose.
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