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Partial cowl repair possible?

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Hi all,

 I am going through the 71 Mustang convertible I bought 4 months ago, I finally got the fenders off and did a cowl leak test. The passenger side Is bone dry but the water came straight in the drivers footwell.  It’s coming in from the far front corner, in-line with emergency brake and headlight dimmer.   As far as I can tell, it’s an area about the size of a golf ball that needs attention.


My question is,  anyone to a partial repair?  my budget can’t handle the expense of tearing the cowl out.My thought is, cut the corner off and get a repair in through the space marked in pic….my welder is coming to do quarter panel next week, might have him cut this corner off for inspection…




Edited by RIBS
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Definitely. Depending on the amount of rust you have it may work. A snake camera can be very useful to asses the situation.

You can look at my thread here for ideas: 




1971 M-Code Mach 1 w/Ram Air, 408 stroker, 285/291 0.558" roller cam, Blue Thunder intake, TKO600, Hooker headers with electric cut-offs, FiTech EFI w/ RobBMC PowerSurge pump

Strange center section with Truetrac, 3.5 gear and 31 spline axles, 4-wheel disc brakes

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It can be done I guess but you are proposing a very small hole to work through. I am currently working both sides of my cowl and am cutting the corners off to get good access to the inside. I also found more rust than I bargained for...

Good luck!


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I know, it's 50% of the pain when there is actually not neccesarily a problem with that part... I removed mine to get inside the cowl:





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I removed the entire top of my cowl.  The passenger side was shot above the heater/ac box.  I'm glad I took the top off instead of trying to do a partial area repair.  Yes it takes time and a lot of work plus the windshield needs to come out but to me it was worth it.  I know that my cowl is solid and rust free.   Looks can be deceiving.



The bottom side of the top of cowl was loaded with rust.  








Edited by Kilgon




"The only dumb question is the one not asked"

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I did a partial lower cowl without removing the upper.  Had to pull the dash, carpet and do a bunch of upside down sheet metal welding.  Not pleasant- however cowl repair is never pleasant.



Edited by Bentworker
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