Mocking the cowl again.
Fitment issue on the passenger side
With the firewall too
Fitment issue. Basically when I line up the outer cowl to the inner cowl, the passenger side of the outer cowl doesn't follow the contour of the "wing".
Drivers side all lines up nice
The outer cowl is aligned to the inner cowl by sticking screwdrivers through the holes where I drilled the spot welds.
If I start by making the passenger side tight first
Here's how the cowl lines up. Note the drill holes only half overlap.
How did this happen? I forgot to clamp the driver's side lower pillar before welding in the inner cowl.
See that gap? It's supposed to be flush. I also suspect the passenger side A pillar front half I welded in isn't quite right, the wing is "toe'd in" if that makes sense. I think the windshield opening is right as there is a horizontal brace right behind it where the dash used to be, and I can't see how that would move. Add all those up with the rotted out bit of metal where the inner cowl and passenger wing piece meet meaning there was no original spot welds for me to line up meant the inner cowl was welded in with the firewall side just a bit too narrow.
Don't think I can remove the inner cowl from the wing panel how I welded it in, there's so much weld joints I'd destroy both panels. I think I'm going to cut the inner cowl in half, or almost all the way though and use the outer cowl to line things up properly. Thoughts?