Firewall repair

[Hemmer]

Little engine bay repair before I spend all my money on coyote parts.


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[Gatordog]

Mine is worse around the hinge mounts. I was thinking about fixing myself, but my Cheap wire feed welder would need to be replaced. What welder are you using?

 

[Broncomt]

Mine is worse around the hinge mounts. I was thinking about fixing myself, but my Cheap wire feed welder would need to be replaced. What welder are you using?

Miller210, little pricey but you can weld tin to thick iron.

 

[rjmunson]

Hemmer,
Found myself staring down the cowl channel in a similar fashion this weekend, packed with rust and flakes, couple of questions for you...

Where did you find a replacement cowl channel or did you fab yourself? Seems like some folks use C-Channel but my online searches don't turn up anything smaller than 10/11 gauge (1/8th inch) which seems about 2x too thick...

Also confirming it looks like you removed the pedal supports, heater, dash etc to get the job done. Any other advice?

Thanks!

 

[Hemmer]

I made it myself I was lucky I didn’t have to do the entire piece I cut the top off and was able to wire wheel the passenger side to clean metal. Had the make one for the drivers side however Didn’t have a heater and don’t think I had to remove anything other than that. Removing the dash would have been nice but I would have to pull the cage and didn’t want to do that.

Hemmer,
Found myself staring down the cowl channel in a similar fashion this weekend, packed with rust and flakes, couple of questions for you...

Where did you find a replacement cowl channel or did you fab yourself? Seems like some folks use C-Channel but my online searches don't turn up anything smaller than 10/11 gauge (1/8th inch) which seems about 2x too thick...

Also confirming it looks like you removed the pedal supports, heater, dash etc to get the job done. Any other advice?

Thanks!

 

[DirtDonk]

Yeah, that cowl design was not one of Ford's better ideas.
I understand leaving an open end for things to breathe and dry out, but that design captured way too much moisture and didn't promote drying well enough. And if you're living in a moister climate, it's hard for the sun to ever catch up.

What are you all doing in that regard when you fix yours? Do you leave the one (or both) open ends? Do you close them off completely? Or do you modify the concept and close those "water catchers" and open the cowl somewhere else to promote drying?

I'm thinking that even drilling big holes under the dash would have been a better solution. As long as water was not actively getting into the chamber it would not leak into the cabin.
But even with the existing design, water still makes it's way into the cabin!

Just wondering if anyone has changed theirs. If it were me, I'd seal it off completely, at least from the corners of the engine compartment.
That's where most rust starts anyway. Even before the floor pans get hit, the overlapping sheet metal starts it's downward spiral to rust-city.

Good luck with the fixes.

Paul

 

[langester]

I had this same issue with mine. I had to replace the whole valley. Its all in my build thread. I welded the top end solid, I am going to seam seal the bottom and drill some holes underneath to let the water out. At least maybe I will have a heads up the next time it leaks!
Thanks for posting up your repair, I bet it will help someone out down the road!
Have a good one!