Upper Cowl Repair / Replacement

[wardhog]

The previous patch job on the upper cowl of the Bronco is starting to come unravelled and rusting.

Wondering if there is a reasonable path forward to repair/replace the upper cowl?

I've been searching around for Upper Cowl replacement posts but have only found posts from people who are also replacing the window frame and surrounding parts.

I purchased a new Cowl Upper Panel from Wild Horses. My hypothesis is the job could look something like this (but wanted to get a sanity check)

1. remove the old upper cowl (this feels like it's gonna be tough?)
2. do some rust control the windshield frame
3. weld the new upper cowl into place

Anyone seen any links or posts on an Upper Cowl replacement?

 

[Rustytruck]

there has been some past pictures of the process. look for old posts. unfortunately it usually involves the under structure and that involves the structure holding the pedal assy.
it also usually involves the structure that supports the window frame and all this intersects with the hood mounting hopefully your only dealing with the top cowl panel and the tops of the front kick panels. The cowl top is not too bad of a repair. depends how bad the under structure is.

 

[Rustytruck]

https://classicbroncos.com/forums/showthread.php?t=266704

 

[Rustytruck]

https://classicbroncos.com/forums/showthread.php?t=283081

 

[Rustytruck]

https://classicbroncos.com/forums/showthread.php?t=66649

 

[wardhog]

https://classicbroncos.com/forums/showthread.php?t=66649

ahh thanks! this thread is super helpful seeing how all the pieces line up together

looks like a lot of work, and a lot depends on the condition of the other pieces once the upper cowl comes off

I'm wondering if the replacement can be done without removing the side fenders