Spot weld a doubler to the inside of the upper A pillar and bond everything.
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RUSH55
SILVER Star
- Thread starter
- #2,342
Who are you talking to?1 question! Are you preserving it like a Mummy or a Dinosaur
. Or do you want it to last another 50 years
. If the latter is the case? Why go overboard???? It took 40+ years to get that Rust, it will take 40 + more for it to ROT
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bobm
WTF, WTF, WTF!!!!
tucker74
Moderator
A wise old pig farmer once told me, “all pigs are rusty and if you think it’s not, you just haven’t found where yet”. Good work on the cowl 
that looks way better than mine! good job getting to it early!
RUSH55
SILVER Star
- Thread starter
- #2,347
And now for an update going into August 2021.
Monsoons have returned to AZ and have made up for their absence last year. Haven’t been able to get much accomplished in the paint and bodywork department other than cutting several 1-1/4” drain holes along the rocker and quarter caps. Picked up a truck bed liner applicator gun. Spent several days tracking down the actual color I’m wanting via a Toyota color code. Out of curiosity, went to my local paint store to see if they could make it in a single stage urethane (acrylic), which he could, in two offerings, the cheaper being $350 for a gallon kit and, Deltron, the other, being…..( (drumroll) )
$800 per gallon.
So then what I did was cross reference my color of choice to the Sherwin Williams online color chart. I was able to match it extremely close. Much to my delight, the industrial SW shop was able to make that exact color in Acrolon. Badda boom! For better or worse, it’s the color going forward. Now the question is do I be extremely vague and secretive like NikP or do spill guts at every step?
Monsoons have returned to AZ and have made up for their absence last year. Haven’t been able to get much accomplished in the paint and bodywork department other than cutting several 1-1/4” drain holes along the rocker and quarter caps. Picked up a truck bed liner applicator gun. Spent several days tracking down the actual color I’m wanting via a Toyota color code. Out of curiosity, went to my local paint store to see if they could make it in a single stage urethane (acrylic), which he could, in two offerings, the cheaper being $350 for a gallon kit and, Deltron, the other, being…..( (drumroll) )
$800 per gallon.
So then what I did was cross reference my color of choice to the Sherwin Williams online color chart. I was able to match it extremely close. Much to my delight, the industrial SW shop was able to make that exact color in Acrolon. Badda boom! For better or worse, it’s the color going forward. Now the question is do I be extremely vague and secretive like NikP or do spill guts at every step?
Spill 'em !
Oh, I see a huge difference! If you want to be able to sleep at night, you’d better get the Toyota color and it had better arrive in a box that has Toyota on it.
Yep, that will work. 
not black enough
How'd that work out for them?
RUSH55
SILVER Star
- Thread starter
- #2,355
Step two of the cowl repair -
Cut out the rusted out areas and put in some fresh steel. Still thinking about laying down another layer of sheetmetal on top of the thinner, pitted metal in the trough. Might be unnecessary with enough layers of primer and paint? Don’t know, it’s not exactly confidence inspiring.
Cut out the rusted out areas and put in some fresh steel. Still thinking about laying down another layer of sheetmetal on top of the thinner, pitted metal in the trough. Might be unnecessary with enough layers of primer and paint? Don’t know, it’s not exactly confidence inspiring.
my thoughts on the layering is it may be a bigger moisture trap than properly treated single layer.. is it a strengthening part?
bobm
WTF, WTF, WTF!!!!
I wouldn't layer any metal.
have you completely settled on paint? have you checked NAPA? i had my local NAPA mix up some single stage 4E9 and throw it in rattle cans for some of the repair work i'm dong.
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