I just removed my windshield and the metal cap over the windshield post from my '66 Malibu convertible. There is quite a bit of nasty rust and even some areas rusted clear through, especially in the corners of the dash, which are also rusted back 1/4 inch or so. The bottom center area of the windshield track is bad, and the top of the cowl (just rearward of the antenna hole in the cowl). I don't know if the reproduction parts are the best way to go, or if I should remove the same portion from my parts car (which is much more solid in that area). There are some spot welds in this area on my parts car (66 Elky), which makes me believe I may have trouble removing parts of it without butchering it all up. Anyone have a recommendation on this?
I have a MIG welder and I'm not afraid to use it. I just wanted some expert advice.

Seems like there are not too many 66-67 Chevelles with this problem. Wouldn't it be nice if GM would have built them correct in the first place?

Kevin C

Correction: not too many 66-67 Chevelles WITHOUT this problem.

Sorry,
Kevin C

I have a complete cowl from a 66 convert. It is in pretty good shape.
The piece that usually fails is available in reproduction. That is the piece right below the glass and behind the vent grille.
Been wondering how your project is going. Was down last spring and picked up some doors and mouldings from you.
Can consult with you on that cowl problem. Have dealt with it before on my 66 Elky.
Karl

Karl,
I will check to see if the repro parts cover the area I am dealing with. I also could cut the same area off that parts car Elky - it has a good cowl/lower windshield area in it. How hard is it to cut it out? I am afraid I will butcher it up - how do you recommend cutting it - air chisel, 3 inch cutoff tool, cutting torch or other? If it is a huge pain to remove, then I would entertain using yours.
My project is going well. I brought the car home in June after the body shop finished the frame transfer. I welded in all new trunk parts, patched up the wheelhouses, welded in 2 new rear quarters, and now I'm working on the windshield area. The rear half is in primer. I got some nice OEM doors from a guy who had them in storage since '76, they are primo condition. It's coming along nicely and it gets more exciting to work on all the time! Thanks- Brian

The lower windshield filler is welded to the cowl and the upper metal dash panel. You will destroy it trying to remove.
When my 66 Elky got its' dash repair, we used a repro filler and a upper metal dash from another car.
The installation requires a great deal of caution regarding fit of cowl grille, R&L w/s pillar caps, upper metal dash, fenders and hood.
The original filler was spot welded in place, bedded in a water base caulking. That is one of the reasons they rusted out so badly.
It will probably be easier if we talk on the phone. Let me know if you need my phone #s
Do you still have that seat?

Karl

Karl, where you been hiding?

Work--20,000 miles on the "van", new grandbaby, E-Bay, it is always sumthin!!

Brought back cars from Texas, Missouri, Iowa, and Indiana. Plus a couple of "parts" runs, including when I met Brian in this post.

By your location it appears you finally made the move.
Hope things are going well.
Karl

Originally posted by more ambition than brains:
Work--20,000 miles on the "van", new grandbaby, E-Bay, it is always sumthin!!

Brought back cars from Texas, Missouri, Iowa, and Indiana. Plus a couple of "parts" runs, including when I met Brian in this post.

By your location it appears you finally made the move.
Hope things are going well.
Karl Id hate to see your parts room now smile.gif You gotta be running out of room in the shop by now.

I finally moved down July 2nd. Had a rough start but finally got on at a Ford dealership. Been here 5 weeks now and really like it. Am still breathing smile.gif so its going good...Eric

Karl,
I still have the black bench seat. At this point, I don't plan to use it in my convertible. Not sure what I will do with it- are you looking for one?
Huge swap meet this weekend in Cedar Rapids if you are interested.
Brian

Brian,
Do have interest in seat still. Picked up a lot of stuff this year. 5 cars, including a convert. shell. Had to cut it in 3 pieces to get it home, but have a lot of misc. parts.
Same old timing problems, daughters birthday party this weekend, even missed the last few Northstar Chevelle gatherings this summer.
Kinda pumped though, going to the SEMA show in Vegas soon.
Please let me know if I can help talk you through the Dash-cowl repair.
Glad to hear you have yours back home and are enjoying working on it.
How was the cruise with your bride?
Take Care, Karl