Upper Cowl Issues... 65 B ? You to ?

[stanhope55]

Hi,

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......

 

[Al K]

Ouch! The S.F. has had that area repaired,though not well. IMHO,that looks like a section replacement is in the works. Good luck!

 

[moparker]

I have to do the same thing with my 65 Satellite. I'm gonna try to do it myself also.

 

[stanhope55]

Moparker,

Do you have any pictures of your project ?

Have you been able to secure any replacement panels etc ? Any source's ? Looking like handmade !! Good luck to me !

That window channel area is going to be a very interesting patch ?

I have no clue where to start :blush:

 

[stanhope55]

Al,

What is the S.F. ??

 

[moparker]

You can get panels at Kramer automotive. They are in PA. I have a repop undrside but, I'm gonna try fuse a used panel from a parts car. Both of my sides are weak. Driver and Pass.

 

[5.7 hemi]

Ouch, I'm with ya in spirit.

 

[Al K]

Al,

What is the S.F. ??

Sport Fury(in the avatar);typed when I'm too lazy to type S-P-O-R-T- F-U-R-Y,which is a lot. Mine doesn't/didn't look that,uh...in need of repair.

I see myself looking at those same repairs(again) down the road;better start looking for a donor firewall to set aside.

 

[dvw]

My 64 Belvedere had similar problems. Mine was only rusty on the drivers side. I drilled the spot welds and cut the outer cowl 1" left of the cowl vents. I removed and repaired the outer cowl. With the outer removed I fabbed a new lower. Then welded the repaired top back on. My rear glass lower channel was gone. I bent a 90 degree section. I made it curve with a shrinker stretcher. If the entire cowl is rusty I would search out a rust free replacement. My buddy recently replaced the entire cowl on his 64 Polara. It was a lot of drilling and welding but not hard,just time consuming. you can drill all the way thru the spot welds if you chose. Welding a 3/8"-1/2" hole is easy with out having to use copper.
Good luck.
Doug

 

[Al K]

Doug,my issue is similar to yours;just the driver's side. It's looking like your solution might work for me. I'm fortunate to know a couple of good metal shapers that could duplicate the panel. Got any pics of your fix? I've noticed some brown spots by back window as well;I'm hoping that full channel replacement is NOT in order. Lately I'm finding lots of sh!t;my mood is souring. My issue:

BAD place;I don't foresee much driving on potentially rainy days... What a fix;the blue Permatex is a nice touch,don't you think?

Stan;where are you going with yours? Keep us informed,please;I'm sure a lot of this group can both help and benefit from this thread.

 

[stanhope55]

Al,

I have just removed my upper cowl. Some bad some good, although when I look at the pictures it looks worse than it is.

I have outlined the areas needing replacement with white.

I have secured a very good replacement cowl from the south. I feel pretty lucky. Hopefully it fits well :edgy:

I am going to blast this area next week and will have a better look.

I certainly have some panels to make and I am no expert.... actually beginner....

I had an idea..... for example.... the areas I have in white outline in the pictures have varying slopes and rises etc... for me to make these exact with no experience will be a challenge.....

What if I took wax paper and taped it off in these areas and then layed down fiberglass or (any ideas for something else) and made a pattern. Then peeled it and the paper off the metal, put this pattern in a mound of sand and had a piece of replacement metal and started to pound out the pattern ? No one will ever see it under the upper cowl, so close should be good enough :confused:

Could it work ?

Any other ideas, I live remote and don't have a lot of panel makers in my area ?

 

[dvw]

cowl parts

Ok guys I've been hard at working on my project and not on the web lately. I built my own lower cowl and repaired the upper. Al you don't live that far if you would like to see how it was done. Also my neighbor made some upper and lower cowl pieces from a plastic mold. They're not perfect but I think they look better than Kramers. I had one of his and would not use it. My lower was simple to make but did not incorporate the wiper pivot mount as mine is a race car. I do have pictures but need to scan them. I'm flying out to Phoenix to make the Mopars at the Strip cruise to Las Vegas in my buddys 64 Fury convertible. I'll post pics when I get back. If anyone is interested in the handmade panels let me know.
Doug

 

[stanhope55]

Yes let's see them.

 

[Joe Mopar]

Yes let's see them.

Ditto:yes:

 

[JimM]

I'm interested in the panel, thanks, Jim M

 

[gtx69]

Her's picture of mine rusted away both sides

 

[gtx69]

Driver's side

 

[stanhope55]

Holy Crap.... GTX yours is bad as well.. !

I think a lot of guys cars are like this. I am not sure how many guys on here take their own off or get someone else to do it..... regardless....

I hope this forum keeps going. Many of us have the same problem and all of us would love to see a start to finish.... from anyone that could provide it...

Any info for that matter is vital when you are a novice....:tongueflap:

 

[gtx69]

I am having the whole cowl replaced too much work to patch it.

 

[gtx69]

How about fenderwells