I know it's surprising, but the further I look into my car, the more rust I find. The other day I was cleaning up the firewall and found a lot of bondo. I eventually uncovered three different holes: 2 in the upper corners, and 1 by the wiper motor. The upper holes look like I can simply cut out the rot and put in some new metal. However, I don't know how I should go about fixing the hole by the wiper motor where the three panels come together. I have posted links to the pics. Can you guys please give me some ideas? I searched throught the archives on firewall, and didn't find much.

Thanks
Ken

http://home.comcast.net/~grulich69/wsb/html/view.cgi-photo.html--SiteID-1666242.html

http://home.comcast.net/~grulich69/wsb/html/view.cgi-photo.html--SiteID-1666245.html

http://home.comcast.net/~grulich69/wsb/html/view.cgi-photo.html--SiteID-1666248.html

Have a look at this part that has been made recently available:

1968-1969 Top Inner Cowl Panel:

The cowl top vent panel has been available for years but the inner panel has been a problem getting till now! This reproduction will replace the inner rusted or damaged section. The quality is extremely good. Manufactured in the USA!

Note: This item is shipped via oversize and requires a minimum 30 lb. fee which is added to the order.

Do a search on the Classic Industries online store with cowl in box under (search by) item description and 1968 in year.

Thanks for suggestion. I looked at that panel. It sure is expensive at $400.

Can someone explain exactly what the three panels are that come together in this spot? It looks like the inner cowl, the firewall, and I don't know about the third. To me, it looks like the inner cowl could be fixed pretty easy without buying the whole piece.

Ken

Ken,
If you don't get a new panel, maybe think about getting a section out of a donor car. I've never had a 69 Camaro and mid 70's Nova next to each other but that area sure looks real close to a Nova cowl section. If it is the same and you cannot find a Nova the Omega, Ventura, or Apollo should be real close to being the same.
I had a rotted out inner rear roof support on my 74 Nova and I went to the local salvage yard and they wanted $50.00 for a section I needed and that was including having them cut it out of the car. I marked the car as to what I needed and marked it way past what was really needed and after they cut it out they gave me even more than I wanted. After I got the section home I carefully trimmed it down to fit into the area that was rotten on mine. I mig welded my repair section in with butt welds on all of the edges and after grinding it down you cannot tell that the area has ever had a repair.
A concern I would have with replacing an area like that would be getting it into the correct position so the fenders and windshield fit properly. I know when I was replacing both quarters, outer wheelhouses, and taillight panel on mine I had to put the car somewhat back together to see how the hatchlid, doors and other things fit before doing the final welding.
Jim

If Im not mistaken the three panel lines you see on the upper part of the firewall are not 3 seperate panels but actually two. One is the firewall and the other is the start and finish of the inner lower cowl panel, but I could be wrong! :confused:

The areas that need patching seem small enough that I could probably make them out of sheet. Finding donor cars in this area is pretty tough. I will try if I have to though, because $400 is too much for a panel that looks pretty good otherwise. My plan is to blast the firewall when I get the subframe back on so I can really see the damage.

As far the the three panels, I read in another post that is was three. Looking at the pics, the outer panel is rusted completely through, yet there is another panel behind it. It doesn't look like the firewall because it's above the seem. At the seem, it definitely looks like three panels.

I'm basically trying to figure out if I can simply cut out the rotted area and weld in patches. I would like to know what to avoid when cutting, and what is safe to weld to.

I appreciate the responses; I want to know what I'm getting into before I start cutting. I may eventually tear the whole car down, but for now I want to make a safe repair.

Thanks
Ken

You think you got it bad, just look at the rust on my cowl at the windshield. I may end up buying a new upper inner cowl panel and patching myself.

http://www.scullyevans@groups.msn.com/scullyevans/johnnyscamaropics1.msnw?action=ShowPhoto&PhotoID=122
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