Reworking the cowl

The late model Corvair's cowl area typically doesn't stand up well to more than three decades of exposure to the elements. Eventual failure of the original windshield sealant allows moisture to invade the area at the base of the windshield and rust forms and eats its way back into the metal dash. Anyone buying a Corvair should check this area for evidence of rust damage and be prepared to invest in repairing the damage and resealing the windshield. The adjoining cowl area and the door jams are important to the structural integrity of the Corvair's unibody. As we'll see, Rick thoroughly reworked both these areas, in spite of the fact that body work isn't his favorite activity. The work wasn't fun, but it was essential to a good result.

Fortunately for Corvair restorers, parts are available to repair critical areas. Rick got the replacement panel in the photo at right from Clark's Corvair Parts. He cut and ground out the bad metal, as you can see by the holes in the dash area, and welded in new metal. Since he didn't intend to use a front mounted radio antenna, he also welded closed the antenna mounting hole while working on this area of the car. Surface rust was removed and the affected areas were coated with Corroless paint. Restoring the cowl area required many hours of work.

Precise positioning of the replacement piece ensured a good fit of the windshield and fresh air plenum cover, which at this point, was not yet in place. Careful preparation of the dash area followed, after which it was painted black to match the new interior color scheme.