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Well, my cowls don't leak, but knowing that Ford didn't paint them, and they are prone to rust, I figured I would nip the problem in the bud before it bloomed into disaster. After all, I'm not really looking to rebuild this car ever again.

Here's a picture of the driver's side cowl before I started:
http://www.knology.net/~dorner/images/lhcowlbefore.jpg

I cut open the side and peeled back the metal to expose the hats.
http://www.knology.net/~dorner/images/lhcowlcutopen.jpg

I was happy to see my hats were in good shape. Now it's time to treat the hats so that future generations can enjoy dry feet. I cut the handle off of a brush, put on some rubber gloves, and painted the base of the hats with POR-15.
http://www.knology.net/~dorner/images/lhcowlpor.jpg

When the POR-15 cured, I applied Zero Rust since I had some lying around. You could also use fiberglass resin or even roofing tar. I didn't want to use roofing tar cause it might stay sticky and catch debris.
http://www.knology.net/~dorner/images/lhcowlzr.jpg

Then I pulled the flap closed, carefully welded it in position, ground the welds, and applied more Zero Rust.
http://www.knology.net/~dorner/images/lhcowlafter.jpg

Now I can rest easy knowing that all my efforts to build a fully restored car won't result in wet feet and rusty floorboards.

Thanks to Torquewrench for talking me into this step. I really didn't want to cut those sides, but now I'm glad I did it.



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Hey great job!!! I'm half way through doing a similar repair. Much easier than pulling the windsheild and cutting 100+ spot welds..
Dan

every man must have a toy
98 Dodge Ram (mobile tool box)
97 Grand Cherokee (family hauler)
66 Coupe 289/c-4 (The Other Woman)
 

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Shesh, I just use a cowl cover, lol.
 
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I just park my car in the garage and never drive it in the rain...lol. Seriously, nice job though.
 
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That is a nice job. For some reason I never figured doing it that a way. I do believe that will be the route I take next time the fenders are off.
 
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