What's under that cowl, anyway?

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Granny's Duster

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Like many of you I have had a problem with water getting into the interior from somewhere under the dash. I have done the usual stuff such as replace the windshield wiper seals, replaced the windshield weatherstripping, all to no avail. So now since I am going to repaint the car I decided to find out where that water comes from. I am going to start by stripping the paint off.
 

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Here's a view from inside the car. See those rectangularish slots? They let water drain from below the windshield. By the way the dash is easy to remove once the windshield is out.
 

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These slots on the side of the firewall are where the water that enters the cowl is supposed to drain out. The problem is leaves, pine needles, etc. get into the cowl area, get stuck, decompose, and then rot out the sheetmetal above your feet.
 

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Notice on the passenger side there is an open area into passenger compartment, but not one on the driver's side. I have another "parts car" Duster, non-a/c car, that has the round openings on both sides.
 

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So now I cut an inspection hole in the front of the firewall on the passenger's side, and you can see from above that the seam sealer is probably leaking or soon will...
 

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Originally, I was just going to weld the original cowl back in place, but my welding skills are not that good. And since I did have the other car (which I got for cheap since all four quarters were bad), I decided to donor the cowl... Before attaching I decided to epoxy some metal mesh to the underside of the cowl vent to prevent this from reoccuring. Is that too redneck?
 

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So now here is the replacement cowl in place. Speaking of replacement cowls, I wish AMD or someone would repop a cowl.
 

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Very nice photo essay. I am seriously thinking about enlarging the drain holes in the cowl area in my 'Cuda now that the car is apart.
 
I always wondered why they didn't put fresh air vents on the driver's side in a/c cars.
Still don't get it.

BTW those Mopar vents kick *** compared to FoMoCo and GM vents.
 
Great thread! thanks for sharing...
I have the windshield wiper seals ready to install if I ever get that dash out but feel theres some damage under my cowl as well ...
 
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