Question
--Hello Bill
The torque box has been changed along with the floor pans ,the cowl is welded in place . Do you think the only way to get there is take the dash out or should I cut the cowl and then reweld it back on ?-----------------------
Thanks Paul
Followup To
Question -
I have a 1967 Mustang with rust holes under front cowl. how can I get in there ,and what is the best why to repair this problem? THE RAIN IS COMEING IN
Thanks
Answer -
Hello! You probably have a very common rust problem with all mustangs. The areas that are most likely rusted out are called the torque boxes. These are readily available from any number of Mustang restoration parts publications. In order to inspect them, put the car up as high as possible on jack stands. Remove the front tires, and see what sort of access you have to the torque boxes. They will be located directly behind the tires. If they appear intact, take a rubber mallet, and beat on the bottom of the torque boxes. If you hear loose material rattling around inside of the boxes, you have a serious rust problem inside of them. Now, you might need to remove the fenders, or you may need to remove the front floor pans to properly attach new boxes, I'm not sure. My guess is that once you pull back the carpet, you will find more rusty metal, and will also need to replace the front floor pans anyhow. The old panels will need cut away, all surface rust treated with POR-15 rust converter primer, and all attaching areas ground to bare, shiny metal. Floor pans can be riveted in, but TORQUE BOXES MUST BE WELDED!!! They are a structural part of the unibody. Now, If I'm wrong, and the holes are above the torque boxes, you may need to remove all the dash components and/or heater box to gain access to the damaged cowl. Does the mustang have a removable cowl vent panel at the bottom of the windshield? I don't recall. If it does, you may possibly be able to cheat with some seam sealer, but it will eventually need repaired properly. Let me know what you find, and I can give you a better idea what needs done. Bill
AnswerHello again paul! I can't see the rust holes, so it's difficult for me to guess where they are. I doubt that there are repair panels available for a repair all the way up in the cowl tray. I could be wrong, however. If the damage is easily seen under the hood, then that is the place to start. You should be able to cut out the affected areas, and patch her up. If the damage is not visible under the hood, and the damage is visible inside the car, removing the dash components is the easiest route to repair it. I know it sounds like a bummer, but it's nuts and bolts. The dash itself is welded in, but removing all the gauges, heater box, and glove box & door will open up the area, shed some light on the area, and move critical wiring out of harms way. The problem I'm having is I'm guessing where the damage is. The cowl vent tray consists of at least 3 separate pieces of sheet metal, and this tunnel also is where the heater box probably gets it's air supply. If the damage is boxed in with sheet metal, and not accessable under the hood, or inside the car, then you are correct, some sort of access hole must be cutinto the cowl. Hopefully, there is an upper panel that can be spot weld drilled, and removed, on the engine bay side. If that doesn't look to be the case, then CAREFULLY choose a spot to cut access with a sawzall, or a small reciprocating air saw would be better. Save this piece, so you can weld it back into place after the repair. Apply seam sealer around the patches, even if you seam weld them, to be safe. Sealing the area up is important, and may prove difficult, so try to duplicate the construction of the cowl as close as you can.. If it sounds like this is beyond your capability, take her to a pro. It sounds like you have a potential nightmare on your hands. Bill
