Partial cowl repair possible?

[RIBS]

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…

opinions?

 

[tony-muscle]

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: 

 

[Vinnie]

Hi,

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!

Vincent.

 

[RIBS]

The problem is the side upper frame is welded over the cowl cover….

 

[Vinnie]

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:







...

 

[Kilgon]

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.  


 

 

[Bentworker]

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.

 

[GERMYS_72]

I just bought a 72 mach1 survivor, and even the though cowl looks pretty decent (I can still see factory paint in it and only some minor rust), I have a very small water leak coming down the heater box on the passenger side.

Is it more likely than not that I have pin hole rust spot inside the bottom cowl ?

 

[Vinnie]

I just bought a 72 mach1 survivor, and even the though cowl looks pretty decent (I can still see factory paint in it and only some minor rust), I have a very small water leak coming down the heater box on the passenger side.

Is it more likely than not that I have pin hole rust spot inside the bottom cowl ?

View attachment 93501

I’d say yes. Many of our cars get leaks there.

 

[73 Mach 1 4 me]

I’d say yes. Many of our cars get leaks there.

Or it could be the heater core leaking, I had to have mine replaced and it only had 72k.

 

[Bill Perkins]

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.

View attachment 54827

View attachment 54828

Nice Job

 

[The Heff]

Unfortunately, I did not have a choice in replacing my upper and lower cowling. Look at the state of it, that's UK weather for you. The upper and lower cowling was totally replaced but it meant a lot of equipment had to be removed. It was worth it in the end.

I think yours can be saved if its only that small area and paint the whole lot with a rust converter and then under coat it with a good metal protector.
Good Luck

 

[GERMYS_72]

Or it could be the heater core leaking, I had to have mine replaced and it only had 72k.

My leak test involved pouring pitchers of water into the cowl, I didn't turn on the car,

but I might try the camera scope idea and see if I can find it.

 

[California 72]

Glad this resurfaced. One of the reasons I’m considering removing my dash was to inspect that area.
So, is it accessible from the interior? I believe I’m in good shape but, the fact remains the car sat for 3 years, unloved and uncared for by the previous owner. The fact rodents turned it into a tenement has me worried. Again there’s the caveat this is never going to see adverse weather but you can’t plan a pop up thunderstorm along our coast creating some havoc if we’re out enjoying a Saturday or Sunday drive.