Body Repairs: Forward Body Mounts, Lower Cowl Patches

Removal of the firewall provided access to the forward body mounts or “cowl boxes”. Because the lower cowl sheet metal had serious rust damage, it was obvious that the cowl boxes would need some repairs.

The left side cowl box was repaired on the car with patches made from 16-gauge sheet metal.

The A pillar on a forty Ford is a length of 16-gauge angle that goes from the cowl box to the upper brace that supports the hood hinges. The 20 gauge doorjamb is spot-welded to the A pillar so it is not very sturdy. When the door is opened wide, the door check strap pulls on the jamb and eventually either tears out the check strap mount in the door or deforms the jamb. Bitchin' Products makes a cowl saver kit that includes stainless clevis mounts for the door check-strap and steel plates to weld behind the hinge pocket for added support.

With both cowl boxes repaired, the next step was to replace the lower cowl sheet metal. As the photos show, the lower cowl sheet metal on both sides was rusted out and whoever made the repairs displayed the same level of workmanship as found on the rest of the car.

Installing these patch panels is relatively simple. Mark the cut line, cut off the old panel with a die grinder and cutting wheel, tack in the new panel and then final weld it.

Cowl Saver: Bitchin' Products (http://www.bitchinproductsinc.com)

Lower Cowl Patches: EMS (http://www.emsautomotive.com)

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