Any tips? Rusted out cowl-firewall-doorjamb. *PICS*

[Bulldog69RT]

These pictures are after taking to it with a wire brush. Any tips? I know most of this won't be seen once the car is back together.

[ACUDANUT]

Wow, major problems there.  You might be on the next mission impossible, to find a donor.  However, a good sheet metal worker, might be able to fabricate some pieces.  Is there daylight under the dash ?

[Bulldog69RT]

The rest of the car is solid. Ive put new floors and trunk in already. This seems to be the worst of it. If you dont count the trunk gutters and the tail light panel. Here is where Ive gotten so far today... I'm Just going to go piece by piece. I cut the lower panel until it was solid, then made a cardboard stencil to use to cut out my sheetmetal.

[Ryan]

This


https://www.autometaldirect.com/store/productdetail/360-1466/66-70-B-Body-Upper-Cowl?view=productdetail&stockNumber=360-1466&BOMReference=&selectedcat=Upper%20Cowl&prod_cat=360&desc=66-70-B-Body-Upper-Cowl

[Bulldog69RT]

well hell. right on! Thanks man

[ACUDANUT]

 Damn, BUY it.  I did not know they even made those.

[adauto]

I got a 68 parts car if it helps???

[Hemidog]

Might aswell replace the lower part too while you're at it....
https://www.autometaldirect.com/store/productdetail/360-1466-1?view=productdetail&stockNumber=360-1466-1&BOMReference=

[Bulldog69RT]

I got a 68 parts car if it helps???

Thanks man. Ill keep your parts car in mind. I'm going to replace the whole upper for sure. the vent on top is damaged anyways and i was clueless of how i was going to repair it. Looks like I dont have to. I guess I can pull the dash out while Im waiting on the cowl.

[Bulldog69RT]

I got the dash pulled. Not as bad as I was expecting. mostly surface rust. Im still debating the lower cowl. I guess Ill see once I get the upper off.

[green69rt]

Here's how I did mine.

http://www.dodgecharger.com/forum/index.php/topic,54582.msg867202.html#msg867202

[Bulldog69RT]

Thanks! Looks like Im going to be doing about the same as you. Looks like you are going to have to do some frame repairs? Or is that just my eyes? If you do have to do some repairs post some pics, because I'm going to have to do some repairs to mine under were the battery tray was. Nice Charger you've got there by the way!

[Troy]

I've been trying to sell a complete 69 (A/C) firewall/cowl for a year or more. It's still welded together...

Troy

[Bulldog69RT]

What are you asking for it? any pictures?

[lexxman]

That's some major work I think AMD sells those part as was already suggested or try and get some good use stuff.Either way you've got a lot of work to do.

[Barwell]

Join the club! I am going to use the AMD repops.

[Bulldog69RT]

  Cool man! Mine looks similar to yours right now. I got the upper cowl off and I'm going to repair the lower cowl. I'll be purchasing the upper cowl from AMD as well. I gotta fill my propane tank up first for the house.  
Did you sandblast the firewall? Im trying to figure out if im going to sandblast it or what.
Post some pics when you get your panels!  

[67Charger440]

Mine was similar so I patched some in from a good donor.  One vent area was toast, so it got the big patch, and I still have to do the base of the A pillar on both sides.  I didn't want to remove the entire cowl to reduce the chance of something moving out of square.  The entire upper will get replaced from the same donor, but as a solid piece.  No patches on exterior panels.

[Bulldog69RT]

Looks Good! 

[Bulldog69RT]

I started repairing the lower cowl today. Good sized rust holes. But its coming together. I wish they sold just the chimney piece. I need one!

[Barwell]

Yep I blasted the firewall. Here is why I needed to replace the lower cowl. Dang mice!. I am fitting the lower piece right now will post some pics tomorrow.

[Bulldog69RT]

Ya, mine had a mouse nest in it too. I might be getting a good lower cowl section from a guy. I hope, it would save me a lot of time and money.

[charger_fan_4ever]

How are the door hinge pillars ? My cowl was rusted out along with the door hinge pillars.

Some shots in my thread of it exposed.

http://www.dodgecharger.com/forum/index.php/topic,71829.0.html

[Bulldog69RT]

The only bad spots in the door hinge pillars are on the bottom back corner and the top of the passenger side where it spotwelds to the lower cowl. I have a donor piece for the top passengerside and the lower holes look like they are going to be an easy fix. Just a couple flat square pieces of sheetmetal, hopefully, I havent grinded into it too much yet. Ill post some pics of the progress, Ill hopefully get some more work done this weekend. I didnt have any power all last weekend. (northwest snow storm 2012) 
Keep the pictures coming on yours. I have the same issue that yours has at the inner fender and frame rail. Thats next once I finish the lower cowl and pillars.

[charger_fan_4ever]

if the lower of the door hinge pillar is rotten chances are the top side of the rocker underneath is soft too. Mine needed a patch the length of the pillar on the topside of the rocker.


DSCN2432 by moparguy55, on Flickr

passengers side same thing rotten under the hinge pillar.


DSCN2371 by moparguy55, on Flickr

The crappy part was the rest of the passengers rocker looked good. Once the top was patched and the new donor pillar put on hit the rocker with sandblast about 1/2 way of the door to find holes all the way through it. Back to AMD for a full rocker