Any modifications needed to make a proper repair on this 66 cab?

[msg]

Looking for advice here, this area of my cab is needing repair and rather than start cutting and making it as close to original as I can...is there a better way to repair this so it dosent happen again? Looks like the gap may be intentional for the rain to channel from that spot in the windshield, didnt know if seam sealer is the best way to keep this from happening or if some other modification would be better.



A view inside, under the dash.

[Nsanehotrodz]

You better remove the inner fender brace under the dash and see how bad that is. Then make a game plan.

[Softpatch]

looks like a windshield gasket leaked for years
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I don't see any stuctual damage if your not going back to stock or show quality
you could weld and sand
OR.....
this is were Seam sealer could be your best friend
they make some great product now that was not avalible say five years ago
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[urmyboyblue]

I removed the vent duct and replaced the metal under it rather than coming from inside the cab. That way, I could treat the metal on both sides- no blind areas that don't get any kind of rust proofing. Takes time and basically sucks, but it guarantee's no rust remaining in those areas.

['63GENIII]

Ive basically have the same thing going on with mine. I had thought that maybe there was seam sealer there that was removed when the PO painted it years ago. They had removed it from the gutters and I have work to do there as well. Im hoping to seam seal both places this winter after I clean up the metal. It looks like the rust is a little deeper on yours than what I've seen on mine. Im going to try to prime / seal the joints, then seam sealer, then paint. On the inside, I soaked any areas that were rusted with Rustoleum Rust Reformer. Short of getting the cab acid dipped or blasted, I didn't have many choices but to seal as best as possible.

[msg]

Thanks guys, I have been slowly getting this truck restored and I guess removing the vent duct is in my case the way to go. Im not going for show quality but I just dont want to have this come back and bite me later.

That gap between the panels in the 1st pic, that had me wondering if that gap was intentional as a drain channel, or just misalignment or something. I wonder if welding those panels more seamlessly together would prevent this from happening again?