[falconhell]

g'day almost finished a complete strip back of my 66. had to replace just about every panel on the car, not because they were stuffed but had bog in almost all and had been hit in back right and front left some where in its life also doin it as a show car and wanted nice straight metal to paint over hadn't even thought about doin the cowl area {out of sight out of mind} but after seeing your repairs i'll be pulling the guards back off and cutting into the ends for a close look before it gets paint.

[falconhell]

yes we are going to flat sheet over the cowl grills, 1 to keep water out of the area and 2 i like the smooth look of that area when its been done.

[66 restomod]

Lots of pictures of the repair on our webpage:
Cowl Repair

The 66 had been parked in a container since 1978 at the construction site. Lucky for us it had not been exposed to the elements for the last 30 years.
We ran a garden hose into the cowl and made sure it drained out the fenders and checked for leaks inside the car but found NO water. We have a rare Mustang that has not rotted out the cowl or tophats.
We decided to use the "Tin Can" Method to check them out by cutting the end caps and bending them up.
The cuts were done with a 4 1/2 angle grinder and a 1/16 inch thick cutting wheel. To finish some cuts, a hacksaw blade was used.
We used Rust Encapsilator on all the metal to stop rust from forming. All of the metal seams and top hats were coated with seam sealer (Eastwood).
After coatings were applied, we MIG welded the cuts back together, ground down the welds. We then applied paint and seam seal on top of the welds. The area is covered by the fenders so it will not be seen.
It took 1 weekend to complete.
If the 66 had needed new top hats installed, we were going to extend the cuts towards the center of the car and follow the procedure from this link:
Boyd's Mustang: Cowl repair
Luckily, we did not have to!!!


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Christophers 66 Mustang Restoration and Modification