Cowl repair

JeepGuy · Oct 15, 2021

Does anybody make a prefit/fabricated fix for the lower part of the Windshield Cowl that seems to rust out on all these Bronco's? I have a couple different ideas to address the issue, but was curious if there is something already out there. Mine isn't really that bad but the surface has taken a beating over the years and it would be easiest to address it now before I really start bolting it all back together.

Below is what I'm dealing with and area I 'm looking to either ignore completely and move on.... or weld in a plate eliminating the channel.

Rustytruck · Oct 15, 2021

that channel is structural it holds up the steering column and peddle assembly. before patch panels people would weld in a piece of structural tubing. I'm sure the lower piece is available as people are making new tubs.

hsach · Oct 15, 2021

I don't know if they make the channel piece or if you have to fabricate it, but the name of your picture is great!
"firewall water collector thingy" LOL

JeepGuy · Oct 15, 2021

hsach said:
I don't know if they make the channel piece or if you have to fabricate it, but the name of your picture is great!
"firewall water collector thingy" LOL

I call it like I see it.;D

JeepGuy · Oct 15, 2021

Rustytruck said:
that channel is structural it holds up the steering column and peddle assembly. before patch panels people would weld in a piece of structural tubing. I'm sure the lower piece is available as people are making new tubs.

What I'm thinking is just welding in a flat piece that basically covers the channel so there would be no valley there. I'm not interested in cutting it out. Looks like someone tried that long before I owned this Bronco, and I know other people have done the same thing essentially making it slightly pitched toward the engine compartment. I was just more curious if any of the vendors have gone as far as actually making a template or precut panels to fit in.... kinda like you can find to box in older C channel frames.

Scotty · Oct 15, 2021

I think what you're describing was close to the original design. The rear of the 2 cowl pieces extended to base of what Wild Horses calls the "windshield frame cowl panel". I guess yours was cut out so that someone could put down a rust convertor and/or allow it to breathe/vent/evaporate.

These are 2 replacement pieces I got from Wild Horses about a month ago. I'm considering adding several holes to the bottom of the channel/trough to allow drainage.

freemanrebel · Oct 16, 2021

Yes its available. I started with trying to replace a small section in the cowl with new metal only to find it had rusted through the trough part of the windshield support. I replaced both the windshield support and cowl with all new metal. Just make sure you get the right year for yours there are slight differences. 66-67 where different from 68-77 and some vendors list the cowl pieces as good for 66-77 which isn't necessarily true.

Rustytruck · Oct 16, 2021

Make sure to use the seal on the back of the hood an where the water runs off the end of the seal and runs down the fender make sure the end of the cowl is pitched enough to drain off the end of the fender instead of running into the end of the cowl channel.

EPB72 · Oct 16, 2021

JeepGuy said:
What I'm thinking is just welding in a flat piece that basically covers the channel so there would be no valley there. I'm not interested in cutting it out. Looks like someone tried that long before I owned this Bronco, and I know other people have done the same thing essentially making it slightly pitched toward the engine compartment. I was just more curious if any of the vendors have gone as far as actually making a template or precut panels to fit in.... kinda like you can find to box in older C channel frames.

https://www.wildhorses4x4.com/product/Windshield_Frame_Cowl_Panel/bronco_Windshield_Parts

THIS,,,/\/\...pretty easy to do but then you'll have to deal with the windshield hinge as well...was oing to repair mine like you said but the more i poked at it the more holes i made.......

Cowl repair

JeepGuy

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Rustytruck

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hsach

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JeepGuy

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JeepGuy

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Scotty

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freemanrebel

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Rustytruck

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EPB72

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