Garage time
 

The temp here got to middle 60's :cheers: and it should be good for a couple more days and then I'm sure it'll snow, gotta keep plugging away - so I'm outa here to do the other side now!

Update 3/13
 

More rust! on the other side cowl! Happened to be the lower section below the air vent opening that rusted the worst, may need to replace with a patch :(
I did get out the ol fiber disc and cleaned the parts I could get to and they came out pretty good, still need to blast the area I can't get to and POR15 em.
Not too exciting but the weather has been nice and it's progress:thumbsup:

http://img36.imageshack.us/img36/2886/120312126.jpg
Cowl removed and more rust above the patch I welded in:(
http://img692.imageshack.us/img692/5809/120312123.jpg
Drivers side cleaned with fiber disc
http://img689.imageshack.us/img689/4291/120312122.jpg
Ditto, still need to sand blast!
Later,
Michael

I just noticed you have the whole cowl removed from your car. Was it that bad of shape? Also, are you going to smooth your firewall?

Yeah, the rust had eaten its way through the seams of the firewall by the wiper motor and the upper cowl, and the dash was rusted out from the windshield leaking. Seemed like the more I dug the worse the rust, so .... to do it right I have to replace everything.
I was going to replace the side cowl panels first and then do a firewall panel, not sure if I'll use a DSE or just make one, that will be a first for me :wow:

At least my floor and the rest of the firewall is good ... gotta think positive right? It could be a lot worse :cheers:

I ended up using the DSE panel and modified it. If my firewall had not been beat to death, I would have just used some sheetmetal to smooth it. I wouldn't weld anything till you have the upper cowl fitted. I would fit the upper cowl as well as those sides all at the same time. Once all is lined up, then I would start welding it.

Roger that, I have the cowl assembly in hand and the side cowls should be here Thursday and I'll start mocking it all up before I weld. With the DSE panel did you weld on top of your original or did you cut out the perimeter and weld?
That's the route I was looking at ... don't see the need for two pieces of metal.

I cut out the original panel and trimmed the lip off the DSE panel. It has a folded lip around its perimeter to fit over the original firewall. It took me an easy day to cut out and install the DSE panel. Its easy work. I am thinking of going back and welding up the seam around the perimeter of the firewall now.

Firewall panel
 

Nice, that was my thinking. I had to go back a ways to find this pix, she's come along way since October.

http://img545.imageshack.us/img545/8782/dscn1528d.jpg
Rusted BAD!!!!!!!!!

Later,
Michael

Yowser! Well you almost got it all buttoned up. You'll be driving this summer right?

I don't know about this summer, my job (Fisheries Biologist) has me out and about most of the summer, that's why I'm hitting her hard during the winter. I expect next summer would be a good goal :thumbsup: :thumbsup: