Cowl rust and how can I fix it?

[Joe Watkins]

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Working on my wifes 82 short bed and I finally found my water leak. Under the windshield cowl where the wiper linkage is there is a huge hole at the firewall. Ill try to post pics. Anyone know what im talking about or how to fix it?

 

[eskimomann209]

I have a similar repair on mine. Yours is more similar to @legopnuematic ‘s however....
I’m not sure if you expect any other answer than
You gotta cut and weld. And that’s one of the most “fun” spots. You need to remove your booster, steering shaft/ column get everything out of the way so you can cut that from the engine bay.
But honestly I’d pull the cab off.
You also need to remove the jute interior wall backing move wires .....
basically have a lot of fun.
That’s the only right way to do this.
That body caulk sucked. I chipped all mine out and resealed it after I was done.
I used gorilla construction adhesive !

 

[legopnuematic]

For the correct repair, @eskimomann209 is right in that you have to cut out the ugly and weld in new metal. On my 79 I had to redo most of the firewall, the area around the heater box, the piece above it, the mating area behind the engine, the piece above it, the piece behind the brake booster and the piece above it. Luckily the patches are pretty simple but still a pain in the rear if the truck isn't blown apart already. The most complicated piece is the curve behind the enigne, as putting a curve in a 1 inch radius isn't really easy without a metal stretcher (what I used)

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[Joe Watkins]

Yea i have rusty rockers, cab corners, inner rockers, and floor supports. I think i may try to fix it while looking for another cab. Give me some practice anyways. Thanks for the pics

 

[Joe Watkins]

Do u have a build thread on that truck?

 

[legopnuematic]

Do u have a build thread on that truck?

My truck? Right here - https://www.gmsquarebody.com/threads/1979-big-ten-an-industrial-forest-find.22250/

 

[Joe Watkins]

Thanks checking it out now

 

[roundhouse]

If the rest of the truck is rusted outs too

I’d Scrub it good with a rag soaked in acetone or gasoline

Use some good urethane caulk and maybe a small patch panel embedded in the urethane to plug the holes and atop the leak and move on to the next problem

 

[Joe Watkins]

I looked through ur build, that truck was way worse off than mine. I think I can fix this. Another thought.. My truck is a factory non ac truck. So another pro for cab swap