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Thread: cowl repair

  1. #1

    cowl repair

    my cowl was pretty rotten.
    the entire gutter was full of holes.
    there is a replacement patch available, but i went with total replacement
    as i feared my weld lines would be iffy.
    Attached Images Attached Images
    bob moglia
    '72 E sunroof coupe

  2. #2

    cowl repair 2

    first remove the old cowl by drilling out spot welds of dash joint and over fender supports. the trickiest part is to separate the cowl from inner fender as it is a solidly welded lap joint seen in picture 2
    Attached Images Attached Images
    bob moglia
    '72 E sunroof coupe

  3. #3

    cowl repair 3

    prepare the donor cowl. finding a good one is important. thanks to shaun budka (shaun 69e) i struck gold with this one.
    separate all spot welds and strip paint. again the lap weld at the inner fender joint is the hard part
    Attached Images Attached Images
    bob moglia
    '72 E sunroof coupe

  4. #4

    cowl repair 4

    clamp carefully in place, you can't have enough welding clamps.
    fitment here is not too much of an issue like sills or quarters.
    plug weld in place, once again look at how the lap weld is done at the gutter corner.
    Attached Images Attached Images
    bob moglia
    '72 E sunroof coupe

  5. #5

    cowl repair 5

    my windshield channels were really bad.
    i carefully cut out and patched in new metal
    Attached Images Attached Images
    bob moglia
    '72 E sunroof coupe

  6. #6

    cowl repair 6

    to finish, 2 coats epoxy primer.
    next up R sill repairs.
    Attached Images Attached Images
    bob moglia
    '72 E sunroof coupe

  7. #7
    I wish I had your skills Rob, very nice work!

    Early 911S Registry #931
    1971 911 2.2S Coupe Albert Blue
    1971 911 2.2T Coupe Tangerine
    2005 997 C2S Coupe special 1965 slate grey
    1978 911 3.0 SC Targa Silver w/chrome trim

  8. #8
    Senior Member Shaun 69 E's Avatar
    Join Date
    Oct 2004
    Cambridge, MA
    Beautiful job Bob! Really first quality work. Glad the metal went to a good home.

    What's next on the punch list?
    Tru6 Restoration & Design
    69S Targa, Velvet Green
    73T Coupe, Gemini Blue
    Early S Registry #1462

  9. #9
    Senior Member
    Join Date
    Feb 2003
    Los Angeles
    Nice work and photos. Thanks for sharing.
    Bert Jayasekera
    1970 911T - Tangerine Orange
    Early 911S Registry #494
    R Gruppe #167

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