Cowl Replacement Advice Sought

Well this thread is to ask experienced Bronco people an opinion on how I should proceed with my cowl replacement. I've searched threads and haven't really seen this part explained.

The replacement Windshield Cowl Mount Panel (black metal piece) has a raised lip that seems to be interfering with the mounting of both the passenger and driver side replacement Cowl Panels. With the exception of the Left Side Extension, all replacement panels are from Tom's Bronco Parts (not for advertisement, just to inform where parts are from in case there are differences in parts from different vendors).

My question is do I cut/trim/bend the lip on the Cowl Mount Panel at the point where they prevent the Cowl Panels from sitting flush? This is my first panel replacement and I want to make sure I am doing what most of you have done when replacing yours. I know this isn't a perfect Bronco but I do want to make sure the job is done decently. I added pics and circled the areas of concern to try to help out a little.

Thanks in advance,

Massey

I just finished replacing mine and yes you do need to cut, grind, bind and weld to get the new sheet metal just right. I'm out of town for a couple days, but i'll try to take pictures when I get back of what I did...

On that first picture, cut the lip of the windshield mount so the cowl fits snug in place

Thanks for the help. I was hoping that I was on the right track. I'm looking forward to seeing the pics of your work.

I had this picture on my phone that will show you what I did on the passenger side.

Maybe some of these pics will help...

Remember you have seam sealer to make sure all seams are water tight. You won't see this when done, so just make sure the fender, heater vent and such all fits correctly.
I also filled in slowly (as to not heat things up too much) using my wirefeed welder.
You are working with metal and so, if you screw up, you can always do some welding to make fixes and you can hide your mistakes. Practice makes perfect.

Your third and fourth pictures, yes, you want that piece down mated with the kick panel piece, so cut/flatten the cowl piece where needed.

This was what I started with. Gives you a pic of the factory body...









Tore out all the rusted metal. Can't find a close up of the drivers side cowl section.


Then the work began. The original piece in this pic gets replaced later, but right now it is holding up the front of the truck. Threaded rods attached to some hangers I bolted to the hinge points and then up to an I-beam.
Everything was done in sections so I would hopefully always have some known good section to work from.




Later the dash and all comes out, once I have the door posts, firewall and kick panels correct. That is when I tackled the windshield cowl section. It was just a matter of cutting a few welds I had made when attaching the door posts, since I did not weld the lower cowl to the upper cowl, just got it all lined up correct. It became somewhat tedious, but worked out in the end.



Note how that cowl piece (very top of pic below) tapers on the passenger side.


Upper cowl is hanging from an I-beam so it remained rigid as I removed door posts and such, then got it back in place.
I left the hard top in place as well so it kept other pieces in place. And was working with body still on the frame.


I used self tapping screws to hold the lower cowl to the upper cowl until ready for final welding.


The passenger side isn't in the right place yet where it meets the inner fender. But I am
getting stuff clamped in place. Later I replace the cowl piece that holds the window frame
as well. Right now that is holding the whole truck up as those threaded rods are attached to
an I-beam to hold the truck rigid as I got it put back together.



Staps so I could hold the dash in the right place and make adjustments before welding.


More test fitting...

Thank all of you for your advice. This is a little overwhelming for my first project but all the tips and photos help boost my confidence for sure.

Don't worry, it was my first time too and I felt just like you. Just believe in yourself and go slow. Mine took me forever but turned out real nice. You can do it Bro!!! .... Don't rush

Here's some before, during and after pics. I seam sealed, primer and painted it after the last picture and it turned out really nice. Good luck man

You all are some talented individuals, holy crap. I can't believe the talent and knowledge on this forum......it as if some of you were on the Ford assembly line when these trucks were being built!

It isn't going to be show worthy but it'll get the job done. Need to fit the metal a bit more, clean it up, prime and weld.

I tried cowl from 2 vendors. Holes were off for fender bolts and that passenger side ramp was off on both. Ended up drilling new holes. Welding and cutting bending and welding that passenger side. 1 piece cowl at be better but I'm sure you would end up cutting.

Tech screw everything and check carefully before welding. I re- assembled whole body before welding.





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Joe473 said:

I tried cowl from 2 vendors. Holes were off for fender bolts and that passenger side ramp was off on both. Ended up drilling new holes. Welding and cutting bending and welding that passenger side. 1 piece cowl at be better but I'm sure you would end up cutting.

Tech screw everything and check carefully before welding. I re- assembled whole body before welding.

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Click to expand...

Looks great!

Thank you. It was a ton of work. Take your time. Also use SEM self leveling seam sealer if you want to keep the factory look.

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thread interruption

Joe473 said:

I tried cowl from 2 vendors. Holes were off for fender bolts and that passenger side ramp was off on both. Ended up drilling new holes. Welding and cutting bending and welding that passenger side. 1 piece cowl at be better but I'm sure you would end up cutting.

Tech screw everything and check carefully before welding. I re- assembled whole body before welding.


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Click to expand...

Excuse me butting in. If you don't mind me asking; which vendors have you found to have the best fitting body panels? I tried to PM you but your inbox was full. Thanks

Here is what I did today.