1970 Bronco - Windshield Frame Cowl & Upper Cowl Replacement - Advice & Questions

[tonytony9]

Hi Forums,

First, I want to thank the various forum members who have helped me out of the past few months in educating me. I am new to body work and having the knowledge has instilled the confidence to tackle this project.

How it Started: Weird pedal flex when compressing the clutch, wet feet, and rust covered floor pans (falling rust from up above is a better way to describe it). Has led to where we are at.

What has been done: Removal of front fenders, inspection of windshield frame piano hinge, inspection of aprons, kicks, a-pillars. Removal of upper cowl in-progress.

What is next:

1. I spoke to some owners who suggested that the end caps (circled in below image) should be replaced along with the windshield frame cowl. My thought process is, if I can remove the windshield frame cowl without destroying the end caps then I will avoid a ton of potential alignment. To my understanding, the caps set the angle for the cowl. Are there spot welds that can be removed from the windshield frame cowl so I may weld a new cowl to the existing end caps?

2. How should I go about fixing this "lip" which the upper cowl will sit on considering I would like to keep my kicks in place and only patch if necessary?

 

[Joshuasnr]

In my own opinion, You can definitely separate the windshield frame cowl from the end caps by removing the factory spot welds. This is a common approach in high-quality restorations to maintain original body geometry.

 

[tonytony9]

In my own opinion, You can definitely separate the windshield frame cowl from the end caps by removing the factory spot welds. This is a common approach in high-quality restorations to maintain original body geometry.

Awesome thank you. On the driver's side, is the lip I circled apart of the apron/kick panel or the cowl? Wondering how that could be repaired without replacing the kick/apron.