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Cowl
#1
Like many others I also have a rusted cowl with passenger side leak. I'm not really concerned about it because I'm going to paint the car in the near future and will also do all the bodywork I have to. I'm just looking for a temporary solution until I'm ready to bring my car to the bodyshop. 
I already sealed the vents (I don't need A/C) , put rubber under the vent screens, sealed the whole thing with silicone also around when I put them back on the cowl. I had a little leak on the driver side but since I sealed it nothing. The strange thing is that I still have water leak on the passenger side. I double checked the vents and everything is sealed from the outside so water not supposed to enter anywhere.

Is there other locations other than the vent screens where water can enter inside the cowl what I probably overlooked?
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#2
Could it be your heater core leaking, when I have anything wet on my passenger side, that is one of the first things I think of. Good luck with the cowl repair.

Tom
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#3
You could have rusted through sheetmetal somewhere. Suspect places could be at the hat juncture or between the hat and inner fender.

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        [Image: 20160929_171923_edit2_small.jpg]

1971 M-Code Mach 1 w/Ram Air, 408 stroker, 285/291 0.558" roller cam, Blue Thunder intake, TKO600, Hooker headers with electric cut-offs, FiTech EFI w/ RobBMC PowerSurge pump
Strange center section with Truetrac, 3.5 gear and 31 spline axles, 4-wheel disc brakes
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#4
Heater core is a possibility
So is condensation from AC
Also, rot under the windshield creating a hole into the cowl is always a possibility (pretty common).
Last thing is that the cowl has an opening on both the driver side and the passenger side that ports inside the fenders.
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#5
In this thread I show how I fixed the rust of my cowl. Look at the pictures there and you can see some areas where the sheetmetal was rusted through.
https://www.7173mustangs.com/thread-my-m...owl-repair

        [Image: 20160929_171923_edit2_small.jpg]

1971 M-Code Mach 1 w/Ram Air, 408 stroker, 285/291 0.558" roller cam, Blue Thunder intake, TKO600, Hooker headers with electric cut-offs, FiTech EFI w/ RobBMC PowerSurge pump
Strange center section with Truetrac, 3.5 gear and 31 spline axles, 4-wheel disc brakes
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#6
When Does it get wet?

1) After Rain or car wash?
2) After driving ?
3) all the time
4) After long AC runs?

If After driving, you may bypass the heater core and see if it stops.

You might also crawl under the passengers side firewall and stick a wire up the drain hose to make sure it is clear.

Sometimes(especially with cowl rot, the heater box drain will get clogged and water will accumulate in the heater box.  It can spill out when rounding corners, etc.

Good Luck

kcmash
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#7
I don't think that the heater core. It only leaks when it's raining but the water definitely coming from the cowl (through the bottom of the heater box what is already rusted out).
Under the windshield is fine. I checked the repair guides on the form but unfortunately I'm not that skilled working with metal. 
That's why I try to do temporary fixes until I'm ready for the paint/body work.

The frustrating part is that I already filled some holes inside the cowl and already sealed the cowl vents completely and it's still leaking.
Assuming that the whole cowl sealed from the outside perfectly it wouldn't matter how bad is the bottom when there's no way that water can get in. But still find a way to enter somewhere.
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#8
I made pics what I did before. Like I said I don't care about how it looks like because the car will be stripped for the bodywork. I just want to keep the floor pan in good shape to avoid any additional work.
The first is the sealed cowl and the second is the pass. side fender where I smeared a little polyurethane. Still thinking about where the water can enter...

[Image: IMG-20190701-093726.jpg]
[Image: IMG-20190701-093749.jpg]
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#9
All it takes is one tiny little pin hole to let the water in. I am betting under the edge of the windshield. I have seen lots of rust in there when you cut the windshield out.
Might also be the roof rain and running down the A post and in the car. There are several large rectangle holes that locate the drip rail molding. Ford used a sorry foam tape to seal that area and it never does. My brand new 73 leaked the day I got it filled the floor with 2" of water.
I use the strip caulk by 3-M instead of the tape.


When a man is in the woods and talks and no women are there is he still wrong??
Tongue
David
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#10
(07-01-2019, 09:42 AM)Carolina_Mountain_Mustangs Wrote: All it takes is one tiny little pin hole to let the water in. I am betting under the edge of the windshield. I have seen lots of rust in there when you cut the windshield out.
Might also be the roof rain and running down the A post and in the car. There are several large rectangle holes that locate the drip rail molding. Ford used a sorry foam tape to seal that area and it never does. My brand new 73 leaked the day I got it filled the floor with 2" of water.
I use the strip caulk by 3-M instead of the tape.
Thanks, I'll check the edge if the windshield. I just did the weatherstripping not so long ago. Also took apart the drip rail. I also put silicone around the drip rail where it meets the body just to seal everything temporary. As far as I see the edge if the windshield where's a gap between the dashboard at the edge of the pillar is dry in rain.
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