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9 hours ago, jkelly said:

When you guys mention Roloc discs are you talking about the bristle ones or the flat ones? I've used the flat Rolocs. They do work well on flat panel surface rust. Never used the bristle ones.

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Earlier I mentioned the 3M bodymans bristle disc, the purple ones. They are awesome for irregular shapes, or materials that overload sanding or convoluted disc (IE undercoating, seam sealer). 

https://www.3m.com/3M/en_US/company-us/all-3m-products/~/Scotch-Brite-Roloc-Body-Man-s-Bristle-Disc?N=5002385+3293083481+3294297763&rt=rud 

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On 10/25/2017 at 4:31 PM, LLave said:

I am going to work on my cowl this weekend. I am going to look around with a borescope and see how it looks in there. Then make an effort to not get too crazy.... Most Z's have a little rust, if it's no big deal I will treat and encapsulate. Last time I said that, I ended up cutting out half the wheel well under the battery tray. 

I drilled the spot welds in the cowl vent cover yesterday to get a better look at mine. It's pretty rust. I'll probably cut the vent tube out and see what I can fabricate to replace the rot in there. Hopefully yours wasn't too bad.

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That looks good! Looks like there was probably a good bit of rust there to warrant that kind of repair! Did you guys cut away the metal covering over the entire cowl area for better access?

Mine has some holes around the inside where the vent tube meets the cowl area floor.

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16 hours ago, seattlejester said:

Oh man you are going all out. 

V-fib did the same repair. His had actual holes.

I roughed out the shape for him and put in the curves and suggested he go out and grab a box section for the vent chimney. He welded it in.

 

Good idea on the box section too. I think I have some laying around here somewhere.

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1 hour ago, jkelly said:

Good idea on the box section too. I think I have some laying around here somewhere.

It really is just designed so that you don't pull in water into the car with the fresh air. If you really want you can match up to whatever heater/blower you plan on running, but yea a box section is way easier to work with then trying to use use sheet metal and spot weld.

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I ended up just drilling the spot welds from the bottom side and removing it to sandblast it and sandblast around the cowl area. I'll just spot weld it back in from the bottom. It has a few rust holes in it. I think I'm just going to fill these with body filler or something easy, instead of welding them.

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1 hour ago, seattlejester said:

That area actually sees a fair bit of water. I would definitely do more than body filler. You have it out, why not weld the holes shut or patch it up? Then you could seem seal it afterwards.

You make a good point. Why cut corners now? I'll use some copper backing plate since the metal is so thin and just weld it up.

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