old seam sealer in cowl....yay.

[frotosride]

So I thought that I had an issue and I noticed a little rust on a few places behind the engine on the fire wall. However, with all the runaway clouds from the tropical storms and hurricanes on the east coast I also have wet floor boards. I don't plan on using seam sealer because I want it to last for as long as possible. Instead I'm going to use windshield sealant after I finish cleaning it all out. The good news is that I have cleaned out half the sealer and the cowl is rust free and the floors just a slight bit of surface rust. Good thing I found this before I replaced the interior. any hints on patching a few places on the fire wall minus bondo and chicken wire are welcome.

[hotrod24]

 Yep go to a junk yard and see if you can cut out the places of the fire wall you need or Like I am using just for now. Fiber glass...

[frotosride]

Didn't think about that. it would definitely save me some time forming metal but I'm guessing it will be hard to find one good enough to spend the time cutting out....

[sphinx]

I'm fiberglassing the 1/4" and less spots under the dash and engine bay on mine.  Then refilling the getter channel with a layer of fiberglass then cover that with new seam sealer.  I have a couple of larger spots above and below the blower box that will need new metal.  I also have to replace the floor plan on both sides.  My truck sat for 6 years with leaves and funk in the drain channel so it rusted through and let water in the cab.  Good luck.  I wish someone would make a "seam filler" seal that could be glued in place with urethane for the cowl.

[frotosride]

looks like I caught mine just in time. So far I have only one cancer hole that's almost 2" wide and 1/2" tall. Man I wish I had a welder...!!

[frotosride]

So I made a little progress on removing the old seam sealer and exploring how big the rust hole is

[frotosride]

After removing the rust that I could actually get to I used Triump to stop the rest of the rust and I plan to use quick steel to temporarly seal the hole since it will be a few years most likely, before I pull the engine and do a modern swap.

[frotosride]

Oh and some gasket maker to seal it all up. once I'm done permanently fixing the hole I will use window sealant to permanently fix the issue.

[bake74]

     I would suggest making sure there is not a spot that the water can pool up and stay, especially where you just cut out the rust.

[frotosride]

     I would suggest making sure there is not a spot that the water can pool up and stay, especially where you just cut out the rust.

Great minds think alike. I haven't cut the rust out yet though. The hole that you see is what has been eaten away. Good thing is that it is a high spot and I made it a little higher and then sealed it all up tonight. my methods are temporary but how long temporary last depends on if I make rank anytime son.

[frotosride]

So, I got the cowl finished and thought I was done...but I found both floor boards soaked after 3-4 days of rain. First though was GREAT, Windshield leaking! Well, I took the seat, carpet and jute out to find rust and a few small holes in drivers floor board and the passenger was perfect but wet...so I tasted it..antifreeze, can't miss that taste! I just replaces my heater core less than a year ago so I wans't happy about that at all.
http://[img=http://s5.postimg.org/kykw0avg3/leake1.jpg]
[img=http://s5.postimg.org/hqgen996b/leake2.jpg]
[img=http://s5.postimg.org/hqgen996b/leake2.jpg]
[img=http://s5.postimg.org/xr900871v/leake4.jpg]

[frotosride]

So I found the leak in the top right driverside corner of the windshield and sealed it ith some GOOP. Got the new heater core today and this time I pressure tested it by hooking it up in the engine bay and ran the temp up to about 220* with a 16lb cap. No leaky, leaky!! sprayed the floorboards tranny tunnel and passenger side firewall wit Duplicolor rubberized undercoat about 4-5 coats. Got the air handler back in just got to bolt everything back together. What funn. Replacement parts now adays stink!!
[img=http://s5.postimg.org/hmhzt9eb7/leake5.jpg]
[img=http://s5.postimg.org/xr900871v/leake4.jpg]

[sphinx]

Glad you found the leak.  Sometimes locating it is the hardest part.  I still haven't finished glassing in my cowl yet, just had too many other projects to finish.   Keep up the good work!

[frotosride]

I hear ya I'm still working on putting the air handler back inside the cab because I keep seeing little things that I can do while I'm in there. But at least now the outside should be completely sealed and inside as well. I have no Idea how I did histhe first time wit out taking out the passenger fender well...but I did, never again!! Thanks or the encouragement. I plan on keeping this one driving around on mars when ever we ae predicted to be there. Then again the jetsons' thing never happened so who knows