All done cutting and fab'n, time to weld. Got Cowl Repair Pics or Advice?

[taipeichris]

Hi Guys,

So the time is here, it's summer and I'm looking at that evil cowl rust again but this time I'm going to do it! I'm going to remove that sinister rust and repair not patch my cowl once and for all!

Okay, enough said.

Does anyone have some good photos of the repair process OR do you have some good advice?

Please post what you've got.
Thanks,
Chris

 

[DirtDonk]

I'll be watching this too Chris, as I'm interested in any new techniques or cool pictures to see.
There was a thread a couple of years ago though, where someone posted up numerous shots of different stages of the cowl work. Don't know what search terms would be the best, but you might give it a try anyway.
Seems to me they even dealt with the corners being a bit different from other Broncos that were compared to in the article.

Good luck.

Paul

 

[thegreatjustino]

Buy the new complete cowl piece from Dynacorn for starters


http://broncograveyard.com/bronco/i-14149-windshield-frame-cowl-panel.html

 

[DirtDonk]

Forgot all about that in the heat of the moment. We were just discussing it over lunch the other day.
So there ya go. But I'm sure we'll all miss piecing it together out of small sheets of custom cut and bent sheet-metal and attached with our best "practice welds" I'm sure. %)

Paul

 

[lasadoor]

if you do a search there are a couple of members that have photos step-by-step of how they replaced there cowl. its on my "one of these days" list, too.

 

[taipeichris]

Look what I found on the BroncoFix.com! This post is from one of their NoCal members from 2005 and it looks like a great cowl repair job.

http://www.broncofix.com/viewtopic.php?t=269641

 

[thegreatjustino]

Look what I found on the BroncoFix.com! This post is from one of their NoCal members from 2005 and it looks like a great cowl repair job.

http://www.broncofix.com/viewtopic.php?t=269641

I knew Lars had that write up on there somewhere. For the life of me, I could not find it in nearly 45 minutes of looking last night.

 

[taipeichris]

I search google images to find threads all the time. I really need to learn to weld. . .

 

[u10072]

Yea sell it and buy another....its like having metastatic lymph cancer...it everywhere!

 

[DirtDonk]

Yeah, that's what ehumaui found out with his first Bronco a few years ago. One little piece of rust just led to another, until he decided that the the cowl was just too much to deal with and bought another one with "less" rust.

Paul

 

[taipeichris]

Hi Guys,
So I'm finally replacing the cowl rot and this is a lot of grinding!

So far I'm on grinder number 2...

I'll post photos tonight.
Chris

 

[71massbronco]

Somebody mentioned the dynacorn assembly and if I had an unlimited budget would probably be the way to go. I didn't opt for it, because you still have to buy the lower cowl windshield frame mount. So you are looking at around $750 plus shipping.

It can be a tough go, especially if there is alot of the rusty stuff, can't wait to see your progress and pics.

 

[taipeichris]

I'm just now putting away tools and cleaning up the garage. I've cut out all the old cowl, ground down spot welds, and made one hell of a mess inside the Bronco but the removing part is done.

So far I've invested $55 to fab the flat cap piece with the bend, $6 for a piece 16ga 1x3 box tubine, $20 for another grinder, 15 cut off wheels from HF, and one long afternoon carefully cutting. This will be cheaperthen the $700 new cowl but it really depends on how much cancer you've got.

FYI, make sure you wear a resperator, gloves, goggles, and ear protection this is loud and would be bad in your lungs or eyes.

I'll post some photos tonight.


PS I can't take any credit for this fix idea, I got the idea from the above BroncoFix "Cowl Cancer" write up.

 

[taipeichris]

Can't get the pics to post from my new laptop. ggrrr...

 

[sellitall]

Here's pics from my repair some years ago. It was a BIG job during the resto process, but turned out good.

 

[sellitall]

I also found an OEM cowl to use. It was the best $20 I spent on the build. Funny thing was a few months after I got it all buttoned up Overhaulin' did the same thing on the EB they did.

Here's my build thread so you can enlarge the pics http://classicbroncos.com/forums/showthread.php?t=84003&highlight=inside. One thing I'm TOTALLY happy with my new build is the cowl is 95% rust free.

 

[ehumaui]

Ya Paul, that was my first. At that time no one was selling the entire cowl piece. I had a commercial truck builder fab up the two piece cowl. I even still have an entire cowl cut out of a wreck bronco. I sold the two piece cowl to someone on classic.

Rc