Rust repair?????????????

[americanmusc1e]

this is in the channel on the firewall and inside the cowl, when it rains it leaks inside the cab. the rust in the cowl is really hard to get to. What is the best way to repair this??? My dad suggested filling the firewall channel with seam sealer until it is level and there is no channel (that's what we did on my roof channel). any ideas??? Thanks in advance.

this is passenger side firewall channel, Its like this on both sides


this is inside the cowl right on top of the heater core

[pat123]

iv got the same problem, should be interesting to hear what other people have done.

[wHATANERD]

I've also got the same problem. Subscribing to see what other have to say

[Hottrucks]

seam seal work since you never see it any way......

the big hole I used for radio antenna and fill around it with plumbers putty

[americanmusc1e]

BUMP!!!

nobody has any ideas?????

[rob32472]

PM Ebfabman he can help ya

[Beatcoaster]

Mine was pitted and had a few small holes...Cleaned it all really well with a wire wheel to as much bare metal as possible, naval jelly to kill rust, cleaned and washed down, locktite anti rust spray - 2 coats. Then just did jb weld putty in the holes to plug them up and did 3m butyl windshield sealer in the entire channel...may sound like a pretty ghetto fix, but you don't see it and I have had no leaking issues so far! (seattle rain for months and garden hose test afterwards)

[tim21391]

at harbor freight they sell a "speed blaster" i dont know if u have a harbor freight or not.. but i bought one to use on my 72 build.. and it was 20 bucks.. it holds about a cup and a half of sand.. it works perfect of stripping paint and rust.. thats what i would do.. use that put some rust preventive so it never comes back.. then seam seal it.... like that one guy said u are never going to see it unless your like me and your picky on things..

[jim zag]

I have the same problem on my RUST FREE EBAY TRUCK!!! It might be easier to cut out the area and put a piece of sheet metal from the bottom and overlap the area and weld it from the top and then seam seal it. Any area that is easier to get at I did a butt weld repair.

[vettezx-6]

I'm working on repairing this exact issue on my 71 K20 right now. I am going the route of patching it in with new metal. I basically cut out the upper section of the cowl to gain access. It's pretty simple to remove, other than the fact that the spotwelds are really tough to find when everything is rust pitted. Once the upper cowl section is out of the way it allows easy access to do a proper repair. I'll try to get some pics later.

[americanmusc1e]

the truck literally has a gallon and a half of of bondo on it anyway. I guess I'll probably fill the channel with seam sealer, I'd like to weld it up right, but it wouldn't fit the caracter of the rest of the truck.

[rob32472]

Check out project sweet pea! That will help ya too. He welded the channel on the top solid that will give strength and stop the leaks!

[ebfabman]

Hey Rob I was checking out this thread and it looks like typical rusted out cowl. This is the area under the sheetmetal cavity that the windshield wiper mechanism bolts to, moving toward the windshield from the firewall. Best seen from inside the cab looking up to the windshield area from under the dash. I looked at project sweet pea and the way it was done, while looks good, does nothing or very little to fix these leaks due to rust. This will not be the easiest repair mainly because of where its located, but it CAN be repaired. Unless you start removing some welded on sheetmetal for easier access, its probably "best" or more easily repaired from the inside which means removing the dash and related items to gain better access to the rusted area. I say this of course IF replacing the rusted metal with good metal is the goal. Just cut out the cancer and make patches and weld them in, really no big deal. Just have to be sure they're welded so there is no pin holes and make sure everything repaired is sealed up good.

[ebfabman]

The second pic looks like its directly above the glove box area, which means decent access from the glove box opening.

[craig24671]

cut it out and put new metal in it

[rob32472]

Eb i agree with that what I was trying to say is before I'd slap some seam sealer on as postes I would at the very least do this!

[americanmusc1e]

Originally Posted by ebfabman

Hey Rob I was checking out this thread and it looks like typical rusted out cowl. This is the area under the sheetmetal cavity that the windshield wiper mechanism bolts to, moving toward the windshield from the firewall. Best seen from inside the cab looking up to the windshield area from under the dash. I looked at project sweet pea and the way it was done, while looks good, does nothing or very little to fix these leaks due to rust. This will not be the easiest repair mainly because of where its located, but it CAN be repaired. Unless you start removing some welded on sheetmetal for easier access, its probably "best" or more easily repaired from the inside which means removing the dash and related items to gain better access to the rusted area. I say this of course IF replacing the rusted metal with good metal is the goal. Just cut out the cancer and make patches and weld them in, really no big deal. Just have to be sure they're welded so there is no pin holes and make sure everything repaired is sealed up good.

thanks for the info on the proper way to do it, but unless I have to wait a really long time for my motor, I'll just fill the channel with seam sealer, I'd like to do it the right way, but It would look out of place on the rest of the truck

[bdnga]

Here is just one of the many places I had to patch ....

Mine was just like yours but works inside the cowl.

Those two pieces I carefully fitted, then welded the two together outside the truck.
Next I put it in place and stiched it up with the welder. I used the welding blankets
over the engine and inside to protect the fusebox below.

[jim zag]

Nice repair! It seems like these trucks all rust in different places depending on what part of the country they are in.

[bad6772]

[QUOTE=ebfabman;3339313]Hey . I looked at project sweet pea and the way it was done, while looks good, does nothing or very little to fix these leaks due to rust.

You may have looked at the wrong thread....I had no rust in this area..nor did I cover any up..I just simply shaved my firewall and the run channel its self....

[special-K]

Cut it out and patch it in.There are membvers who cut pieces of cabs and ship from time to time.

[ebfabman]

Hey bad, I think we are on the same page. I can see that you modified your firewall and did not do a rust patch. The pics at the top of this thread show rust in the cowl, thats why I said what you did won't help here.

[rob32472]

Bad... wasnt tryin to say you had or covered up rust just offered a way to stop the leaks other than slapping on some seam sealer and the way you boxed that area will surely stop water and would be better than slapping on some seam sealer and it looks as if it may be something an avg. welder could do with some patience although you did an awesome job and i know the avg guy probably would be able to do as good a job .... I have followed sweet pea and that is on BAD A$$ build great job!

[bad6772]

ebfabman...I got ya....And yes you are right...(capping) the top will not protect against any rust that is underneath....Just hide it for another day.