Need assistance with my cowl side panel

[Hairy W Bush]

After I made my cuts on the panel, I realized it wasn't going to line up like I expected at the post. so I have this big gap that I am clueless on. I attached a picture to show what I mean, along with the whole position.
it actually overlaps the old cowl side halfway. the small patch that's welded is the old part of cowl side panel.

 

[2+2GT]

It's not supposed to overlap the A pillar like you have it set. What you have is really a patch panel, that's only intended to go to the pillar, not be part of it. What you need is the whole piece.

 

[Hairy W Bush]

I know it's a patch. I actually had to trim it down because it was way too long. and I'm pretty sure I didn't cut it too much because it reaches the firewall and rocker points pretty good. (just have to trim the firewall patch obviously)

 

[2+2GT]

Yeah, but now it's too short.

 

[Hairy W Bush]

how is it too short? it's in a decent position considering I take off some off the firewall side, and like I said, I actually have it overlapping some of the old side. I'll have to take a picture to show you.

 

[2+2GT]

Well, in this pic it's about an inch too far to the rear of the car. Or are you talking about the gap at the top, which is caused by your cowl being completely trashed?

 

[Hairy W Bush]

no I'm talking about the gap at the post. I know my cowl is gone...and I was going by that big hole from where it originally was when I trimmed it. It's pretty much where the old hole was.
ok 2 questions. do you think that the flange on the firewall is too big? and is that how it meets the post there; it just mashes down right from the straight upward angle?

 

[2+2GT]

The bottom part of your repair panel is clearly too far toward the rear of the car. Even halfway up, the access hole for the fender bolt is too far to the rear. The hem might be a bit too wide on the firewall patch, but you'll need most of it, to attach the splash shield. Until the side patch is moved to the correct spot, you'll have problems.

 

[Hairy W Bush]

damn I see it now. this whole piece just wasn't made right. because as you can see it's straight where it's hitting the firewall.
what do you suggest? start over with a quality piece?

 

[2+2GT]

I'm thinking your pane is stamped OK, but the bottom edge is trimmed a bit 'off'.

 

[Hairy W Bush]

you're right. I looked and the bottom edge is off. that must've threw my cut off. I'll have to scrap it and get a good one. is the one from cjponyparts the same?

 

[2+2GT]

Yeah, well, I doubt they make them, it looks like an American Designers part. Probably just defective. I've seen that part work just fine, locally.

 

[Hairy W Bush]

actually it's a spectra premium.

 

[palerider94]

Its hard to imagine it was defective. I'm doing mine now and it is a spectra also. In measuring from up against the pilar where hole is to edge of cowl min is 12 1/4 inches. Also the flange on you firewall patch looks wide mine is 5/8 of an inch. To me it looks like you have everything right but the flange is to wide. can you trim it back to get it to fit.

 

[WTFO]

Hang a fender really quick to see if that fender bolt hole lines up at all. That'll help position it a bit better. My car needs the same repair so, good luck and post your solution!!

 

[Hairy W Bush]

it will. that big hole is pretty much where the old hole was. the problem is the inside isn't lining up I guess due to my cut because the bottome isnt straight which is what I went by. I am still wondering how it goes to the door post. from what 2+2 show it mashed down but I can't see how unless I cut it back more. but then the little access holes on the inside will be shrouded and it's diffucult making the cut at the rocker on the inside.