Hey Subie folks,

 

Its been a bit since I've checked in but finally got my 79' "legally" on the road in Cooperstown, NY

 

I scored this sweet thing in a barn not to far from where I grew up stomping through the woods in NE PA.

 

It had 22,7xx miles on it!!! And I'm positive because the old couple that were family friends kept all the receipts in the glove box, even from the day they bought it 

 

Okay enough rant, now the problems. Other than the brakes that I've been re-doing I've come across a mouse nest under the cowl.

Now I've figured out where that mysterious puddle on the floor was coming from

 

I've gotten the cowl off and cleared the nest and found some rot that comes in right underneath the dash. Its a pretty darn hard spot to get to.

 

Any ideas?

 

My first thought is to plug off the cowl area, but not being a talented mechanic could this cause issues with the heater and air flow?

I'm sure I can get up in there with some silicone but just a matter of time before some new holes appear, its not a pristine ride so as long as it doesn't look that bad I'm willing to try

anything

 

 

Sorry I always seem to have issues putting pics up on here

Edited July 15, 201510 yr by NEPASubaru

Cowl rust is not pretty. Check my build thread and see what I mean, there are 3 layers of metal in there! Not sure the best method to do a temp repair as the rust won't stop and it will only be a matter of time before the patch fails. Best guess, fiberglass the area under the dash and have the cowl area cleaned and maybe spray in bedliner? For the most part it's not an area you can get a brush into.

If you need a replacement cowl I have one.

That cowl rust has killed more Gen 1 Subies than any other!

Oh Damn! I dont need a new cowl, its rusted in underneath the cowl area.

 

I though maybe plug up the cowl area just in general, close the openings underneath the cowl, not sure if this affect anything with air coming in tho.

 

I cant let this stop me!

The problem with the cowl, as Datsunrides has mentioned (and repaired on his coupe restoration!) is that there are 3 sections of metal that all come together in the cowl area. If you just repair under the dash area, for example, you will not effectively stop the rust in the other two sections of metal. Such a repair would only last 6 to 12 months before the rust makes plenty of new holes. It will then start spreading down the wheel arches and into the floor area before long.

 

Sad but true... As an extremely temporary fix you could plug it up but you will have to fix it properly at some point in the future.

Edited July 17, 201510 yr by Leeroy

Here are some slightly depressing pictures: http://www.ultimatesubaru.org/forum/topic/97207-my-73-coupe-restoration/page-2

Here are some slightly depressing pictures: http://www.ultimatesubaru.org/forum/topic/97207-my-73-coupe-restoration/page-2

 

That brings back bad memories. Like Leeroy said, if you are seeing rust under the dash, the middle section of metal is probably completely gone at this point. When I deconstructed the cowl on mine, that is what I found. Basically a couple cups of rusty junk. The other bad thing is the cowl is a major structural part of the car. Once the metal starts to go, it will slowly lose structural integrity as the rust gets worse. If you truly like your car, the only real option it to replace the metal. anything else is kicking the can down the road and it's only going to get worse and start affecting other areas.

 

Mark

I literally jumped back in my seat with a grimace on my face....this is what I'm up against 

 

 

I think I need to know my limits and this is way beyond my ability. Come the end of summer I should probably just sell her to some other fanatic

Edited July 17, 201510 yr by NEPASubaru