My buddy and I are trying to get this '68 beast into shape and surprises keep coming up.

The newest one is a rotten cowl. When I say cowl I mean the metal area directly below the windshield attaching itself to the firewall. There is a piece of trim that covers the bottom of the window and partailly covers the cowl area. I was not there when he took it off but I was able to see some damage earlier to one spot that is probably indicative of the whole rotting situation. He described the area as "gone". There is probably still enough good metal to work with though (I hope).

I called Year One and they had no replacement part cowl, called a place in Kentucky and the guy said I would have to either find a good donar replacement piece or fabricate one myself. Since up live up North the first option does not exist. So I guess fabrication is the answer.

If anybody can help me out with these questions that would be great.

What guage of steel should be used for fabrication? Any tips on fabricating this part?

This area is a key element in your front end this is the part that hold's the dash, firewall and cowl all together. So I am willing to go a bit overboard to make sure it is done right.

Thanks for any info

Metal fabrication is something many people are scared of but some basic knowledge can get you started. Two resources you should know about. One is a website called egroups.com which has a metalshapers forum. They are almost all car guys. They can really help. The second resource is Ron Fournier's Guide to Sheet Metal Fabrication. He has two books. Either is probably ok, but go to a book store and look at them to see which is better for you.

Now, to make this piece using simple hand tools, you need to put a bend in the metal where the lip goes under the dash panel. At this point you have a straight piece of metal with a bend in it. Next you need to shrink the part of the metal closest to the windshield and streach the metal further away from the windshield. This will cause the metal to bend into the shape you desire. It is hard to describe this without pictures and without you knowing how to streach and shrink metal. If you email me I will give you my phone number and maybe set you in the right direction. My 69 has this problem. The stainless trim allowed dirt and debris to accumulate and trap moisture, causing rust. There are many ways to solve metal working problems so my opinion will be one of many. Someone more experianced my be able to explain it better. I can also recommend video tapes describing the basic processes involved.

Sorry, I forgot to mention 20 gauge cold rolled should be used.

Hey, Thanks a lot man,

I have good news I have a friend who is a precision sheet metal fabricator in my corner now. I just talked to him and he should be able to help me out. I just gotta buy him a couple of 24's of Bud. Those instructions will really help the process and hopefully I solve this problem.

I noticed the same thing in regards to the trim trapping debris and water its too bad they couldn't have designed it better. Then again not too many Chevy engineers thought these cars would be around 32 years later.

Hey Kris, who's your buddy ??

Sorry to here about the messy outcome, but chin up, for $$$ laid out its bound to have surprises, and you'll only appreciate her more when its all done right.

I know, it hurts for your first purchase, especially when its already mid July, but look at the value these beasts are grabbing lately and when your done you'll have yourself a righteous and valuable piece of history.

-Greg

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69ht383>Smokumchevy
TC member#610
Smokum's '69 pics (http://www.cartogra.com/home/ViewMyAlbum.asp?coll_id=199357)
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I just want to put out a big thank you to my buddy who goes by the handle of Canuck64SS for helping with the Beaumont. He probably never thought an offer to fix the wiring could turn into the can of worms it has become. Hopefully we can somehow get a donar car and fab in a new cowl.

Try the following website for National Parts Depot. I ordered a replacement cowl piece (about $24) for my '67 Chevelle and it worked just fine. Hope this helps. Jeff
http://www.npdlink.com/cgi-bin/catalog_order/catalog_req

[This message has been edited by Badblu67 (edited 07-23-2000).]

Hey Kris,

Whats the scoop ? I here your pulling the car out of Steve's on the weekend. Have you found a solution ??

-Greg

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69ht383>Smokumchevy
TC member#610
Smokum's '69 pics (http://www.cartogra.com/home/ViewMyAlbum.asp?coll_id=199357)
My Homepage (http://www.smokumchevy.homepage.com)
ChevyWorld (http://www.chevyworld.net)

Hey Greg,

Nope, I am not pulling it out this weekend unless it would be better for Canuck64ss that I got her outta there. The word is basically from talking to few people is that the Beaumont body is basically ready for the scrap heap. The good news is that all the good stuff is still useable especially the engine. I will post a picture up of the rust spot when I get my digital camera going and maybe someone can give me some ideas.

Hello Badblu67,

I just phoned NPD (for the second time) and they said they only stock cowl pieces from years 73 and on. A previous time I phoned the guy didn't have the foggist idea about what the part is. Is there a specific part number I can give them? I also ordered their on-line catalog.

Thanks for the help,