jb3829

iTrader: (1)

Finally bit the bullet and tore into this part of the rust hunt. I used a 4 foot steel chain link fence support filed into a chisel in order to scrape the sealer out of the cowl.......it worked great! This is the crud I found underneath the sealer. After cleaning and prepping it with the POR15 system.......I poured the POR15 down the drain, so to speak and coated the rest of the area with it as well. I'm going to follow with some new seam sealer.

micktroup2

Man, you are lucky you only have that much damage. Mine is rusted RIGHT THROUGH where it meets the firewall, which is also rusted through. I have a nightmare to fix...

joshhsi

Did you scrape and replace the sealer from fender to fender? If so, how the heck did you get the sealer in there once you are beyond the vent hole? I have been thinking about drilling the spot welds out and cutting the top off to fix this area.

nosajwols

iTrader: (1)

I did mine end to end, used a scraper and picks etc. by hand to get the seam sealer out. I did it with the dash, wiper assembly, heating and cowl vents out of the car (made it easy to reach side to side inside the cowl). Welded in new metal where required, there was also a pop riveted epoxy bonded repair I did 10 years ago on the firewall side that I left in place, it was still solid.

Sprayed chassis saver using a home made pressure vessel rig (Diesel injector cleaning rig was the starting point) with a brake line as the nozzle throughout the cowl (top, sides and bottom). Poored in additional chassis saver which ran out in all kinds of places (pin holes) but coated and sealed both sides of the metal down the seems (this stuff also bonds like crazy so the two layers and pin holes are bonded now). Then I seam sealed the entire mess.

I was going to epoxy fill the seam (like we did with the chassis saver) but decided not to.

jb3829

iTrader: (1)

I duck taped a paint brush to an old antenna to get the hard to reach areas