I decided to get a new windshield for the 68 and uncovered more work than I had planned on. After removing the lower trim, I discoverd this:

http://www.72chevelle.com/jeffk/cowl1.JPG
http://www.72chevelle.com/jeffk/cowl2.JPG

It appears that the rust didn't eat through to the dash, only the outer panel that you see in the pics.

I remember someone posting pics or a website with a similar repair awhile back. Does anyone recall that or have any advice on how to proceed?

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JeffK ACES #01510
Team Chevelle Gold #72
68 350/Powerglide Ragtop
72 496/Richmond 6-Speed
Jeff's Chevelle Page (http://www.72chevelle.com)

There isn't any secret there. I also remember someone had it on their web site.

You have to fab up a patch panel and weld it in, or maybe find a donor car and work the piece in.

Jeff,

unfortunately this is a common problem with the 68s i have fixed two that where worse than yours. the 68s have that stainless trim that sits on the cowl and traps dirt and moisture. and you know the result after 30 years.

i found 2 69 donors cars and cut the whole top of the dash out with a sawz-all then replaced the parts necessary to fix the rust. both of 69s i found didn't have that piece of trim on them and the dashes where in good shape. i don't know if they came that way or someone took them off. but if you can find a donor 69 chances are it will have a good dash.

i had to replace the whole top of the dash on my car all the way out to the firewall. if you would like some pics let me know i can borrow my dads scanner and send you some of how i did mine. this is a fairly easy repair it just takes some time. there are very few spot weld to deal with mostly just getting your sheetmetal lined up and weld in straight.

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My 68 (http://www.chevelles.com/showroom/68racer1.jpg)
My Engine (http://www.chevelles.com/showroom/68racer2.jpg)

We also replaced the whole dash ('69 donor car), as it was rusted almost thru at the lip and as it starts upward towards the dash itself. Our cowl area was fine, just sandblasted it, and then went thru the POR-15 process. We only used POR-15 Silver under the lip that meets the dash lip and under the trim piece itself, plus under the entire dash itself, plus the inside firewall, and floorboards. Used PPG epoxy primers elsewhere (Finish coat to come).

You could find a donor car and actually cut out the cowl area and dash or dash lip.

Why did we use POR-15 where it didn't show? Quite obvious that regular paint(s) will be subject to water and the elements in general. Once the car is done, we will pull the lower windshield trim often to "Keep It Clean").

We also sandblasted and used POR-15 Silver on the firewall (Marine Clean and Metal Ready first). Sprayed it on (Ventilated area), works great, and looks very "Professional". Now we are installing the Stainless Steel firewall in 4 pieces.

We'll try to post some pictures on the above this weekend.

Hope this helps.


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Team Members Forever #341

Richard, Judy, MAXX2

'69 Elke (Frame Off); GM HO 350/330-Mildly Ported Vortec Heads-Manley Severe Duty SS 2.02/1.60 Valves, Comp Cams Full Roller Package (Magnum)-Custom Grind CS 3315/3316 HR112-.510/.520 Lift, Edelbrock Air-Gap W/750 Performer Manual Choke-Performer 100 HP NOS, March Pulleys, 4L60 (Non Computer) W/Lokar Shifter, 12 Bolt Posi.

Jeff-

Shouldn't you be working on finishing your '70 SS? I hate to say it buddy, but it looks like I'll be finished soon. I thought for sure you would have beat me!

A '68 huh? Don't let it distract you from finishing the '70! http://www.chevelles.com/forum/biggrin.gif

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Gregg Haskin
72 Chevelle SS
ZZ502 Crated RAT
Muncie M-20 4 speed
TEAM CHEVELLE #726 ACES #4486
"PROUD TO BE AN AMERICAN!"
“What the heck are all these extra nuts & bolts for?”

My 72 Chevelle SS Restoration Website: www.wcvt.com/~ghaskin (http://www.wcvt.com/~ghaskin)

No, I didn't forget about the '72. I just couldn't pass this deal up and of course I needed to make a few changes to my liking. Like power disc brakes, intake, carb, headers, dual exhaust, 700r4 trans...

You know, a few changes http://www.chevelles.com/forum/wink.gif

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JeffK ACES #01510
Team Chevelle Gold #72
68 350/Powerglide Ragtop
72 496/Richmond 6-Speed
Jeff's Chevelle Page (http://www.72chevelle.com)