#$@(*&'n rust!

[shdnobetter]

Man, I'm so bummed!I pulled the heater this afternoon to replace the core and found that the bottom of the cowl, next to the vent inlets, has rusted through on both sides! After further inspection I also found that there is perforation in the lower edges of the outer cowl, above each fender. I bought this truck because the floor was solid but didn't think to look under the dash. Now it's looking like to fix it right I'll have to cut off the top cowl panel, patch the lower, inner sections, then weld the outer panel back on. There's also perforation where the roof meets the upper door frame, as well as some behind the cab under the backlite.
I might look for a solid '55-'57 swb Utiline to put on this chassis, as it would take me years fix this rust, given the meager amount of time I have to spend on it.

[Hobcobble]

Man.... do I feel your pain. Living in the Northeast
"rust belt"..... I've seen it all. If the floors are nice, why not
just drive it as is and keep your eyes out for a replacement
cab?
John

[shdnobetter]

If the floors are nice, why not
just drive it as is and keep your eyes out for a replacement
cab?
John

Yeah, that looks like a worthy (only) option at this point. I hope to arrange a business trip to the Phoenix area later this spring; then I could look around down there for another cab.
In the interim, I have to do something about the holes in the bottom of the cowl, as the rainwater runs directly into the cab via these since cleaning out the pack rat hotel. I'm thinking about just patching them with fiberglass.

[motomatt383]

my truck had some issues under the dash area, i just cut out the rust & fabbed some replacement panels out of tin & welded them into place. same for the outer lip just above the front fender. i was pretty bummed but i didn't let it take the wind outa my sails. i could have made it into a project that would have taken yrs, but i ended up having less than a weekend in it. the under dash repair doesn't have to be done exactly back to factory specs, nobody can see it!


matt

[steven]

I agree. I just started welding stuff shut underneath the dash when I did it. The piece doesnt even have to fit correctly, Just cover up the hole.

[shdnobetter]

All good points, but what about stopping the rust process inside the cowl where there is little or no access? Short of cutting it open I was thinking of removing the center grille and getting all the loose stuff off that I could, then drowning it in POR15.

[steven]

Yes, you definitely have to get all of that crap out and dry it out. Mine was loaded with junk, but the sides of the cowl werent rusted out yet. I put rust converter everywhere I could through the top door hinge hole. That should not be open to the cowl drain area, but most of the time it is rusted through. I would clean everything out as good as you can, blow it out, make sure its dry, and spray rust converter everywhere that its not rusted through. Anywhere it's rusted through, I'd fix it.

[surfnuke9]

cant remember who it was, hobcobble, russ or nfury8, but one of them took care of this area with an epoxy (I think) to seal and protect.

I remember the post, just not who did it.

[soopernaut]

I think it was Russ

[demulsion]

It was Russ. Though without the search function, that's not a lot of help...

[shdnobetter]

Thanks to all!

[surfnuke9]

sure it is demulsion, now he knows who to pm and ask about the repair.

[71D100]

I'm about to tackle that very same issue on mine. The drain holes got plugged with junk over the years and held back the water in the cowl. Both sides are clean through. It's mostly around the fresh air vent openings. Some damage to the front of the cowl in the engine bay. I intend to cut away all the rusted panels and weld in new ones. Then POR 15 the hell out of it and seam seal the rest. If that don't stop it, then I don't know what will. I have also entertained the idea of sealing the cowl off all together and making new fresh air vents (or not). The problem with that is no fresh air through the A/C, only recirculate.

I'm starting this soon as the high desert gets to be friggin hot in the summer. 50 Miles from Death Valley

Don't let it get you down. Beat rust at it's game. POR15 and a really nice welder!