I removed that aluminum cover at the bottom of the windshield to discover cancer! It is the 5th picture down on this website
http://www.cardomain.com/memberpage/529898/2
Does anyone make a replacement panel here?

thanks guys

The part you are talking about is currently not available from any source. Goodmark industries produces a part(s) for 64 & 65 but no other years. Why Goodmark or Dynacorn have not produced these for other years is beyond me but... Who knows. I live up north and heaven knows this is NOT an unusal type of rot found in our rides.

From your pic, it's hard to tell the extent of the damage. To determine that, you'll have to remove the glass and clean it all up then you'll actually be able to tell what's up. It is fixable but will require a fair amount of effort.
This area should be fixed using metal and should be structurally sound otherwise it will twist and break glass etc... Also if the firewall area is leaking it WILL get your electrics wet and then you can guess what will happen. Condensation is the real problem here.

Area Description: (based on 64 to 69 design maybe slightly diff 70 & up) This area consists of 4 pieces and sure enough they all come together at the point where it's rotted out. The upper dash panel consist of 2 pieces with a layer of "foam (see culprit)" which is then welded to the rear/upper portion of the firewall at the top of the cowl. The cowl cover itself is an additional piece which is welded in between the layers to the small "L" area at the bottom where the glass meets the cowl.
WARNING the foam sandwiched into the panel is VERY flamable as is that yellow rubbery caulking.

see simple diagram below.
\ <- glass
dash > ==\_
| \___ <- fr. outter cowl
Fwall > |

I hope this helps...

I had to fix mine. Did as Steve said, removed everything, made new sheet metal, bent, welded, hammered, welded some more. Not fun but its solid now with no leaks and looks like factory. NOT for the faint of heart. Oh, the WARNING above, keep an extinguisher handy :D

Call the guys at Sundells, I am in the process of doing the same thing to my 69 and they had the upper cowl piece and the dash board piece. Great guys and good prices for solid used parts from donar cars compared to the hours it would take to fabricate those parts.

churp i hate to bash anyones buisness but here i go. i orderded to dropdown supportbraces and a rear package shelf. what they sent me was rusted junk! that was worse than the metal i was replacing . sundells took there time at sending it then. had to call several times to get my order shipped. HOPE YOU HAVE Better experence with sundells than i had. it was at the north carolina store. good luck

Sorry to hear that, I went to the PA loacation and talked with Norm and actually picked out the pieces I wanted, and ordered a rear bumper brace for my 69 and was vey happy with it when it came in considering its 35yrs old