cowl foam?

[Dreamcar]

I started removing my rusty cowl panel and noticed a foam between the spot welds. What type of foam is this and how do i put some back in when i start plug welding the new panel in? Isn't welding going to burn off whatever i put between the panels?

[Silver R/T]

You want seam sealer not foam, foam absorbs water/keeps moisture and air in resulting in rust. You want to use weld through primer between two panels welded together.

[Troy]

I believe the factory may have used some type of weld-through material as I don't see any other way they could have gotten it so thoroughly in between panels. Of course, they were using real spot welders too (probably a lot less localized heat than plug welds). I am using Picklex on the bare metal in the weld, epoxy primer (loaded up to flow into the seams), self leveling 2 part seam sealer (2 part foam if the gap is large), and then brushable seam sealer on top. I doubt it will leak or rust in my lifetime.

Troy

[Dreamcar]

I think I'm going to use Chassis Saver (think POR-15) on the bare metal on the plenum before the newcowl is installed on top, and of course some weld-thru primer on the edges where the new panel and plenum are welded together by plug welds. Then, I'll use seam sealer on the outside edges.

[Dreamcar]

Just found this..weld-thru seam sealer...this may just be what i'm looking for

http://www.lord.com/products-and-solutions/adhesives/automotive-repair-adhesives/product.xml/1932