The Stovebolt Site Forums The Shop Area Paint and Body Shop Cowl Repair Advice?

I'm working on the passenger side cowl with replacement panels and am having some issues with fit (no surprise there, as many have said that would be the case.

The attached photos show what I'm up against.

With the inner cowl panel mostly in position and matching the curve of the A-pillar, it needs to have more curvature to meet up with the inner-to-outer cowl piece. I think I can straighten the flange at the bottom of the inner cowl panel and get it worked around to match, and run a weld bead between the floor (when I get that in place) and the inner cowl. Apparently the flange is intended to extend down alongside the rocker and floor where it bends over the rocker, but the was no evidence of three layers there when I removed the rusty stuff.

Another issue is the fit of the inner-to-outer to the beads on the inner panel. The top bead doesn't match up with the wide notch in the inner-to-outer. Also, with the inner-to-outer as close as I can get it to position, those notches aren't even horizontal (not a big deal as they'll be mostly invisible.) The beads on the inner seemed to match with the position of the original fairly well. This inner-to-outer is notorious for not fitting correctly. The curvature seems wrong as well, as with it clamped to the match the bottom with the rocker, it's too high to fit the outer cowl depression for the hood. I can whack some off and reweld that. Maybe completely cutting the inner flange off and pivoting it back at the top would fix the notches. I'll definitely need to fix the height issue. A specific question is should the inner-to-outer line up with the front of the rocker?

Surprisingly, the outer cowl panel seems to fit fairly well.

Any thoughts on the order to weld in the panels? Of course, the inner-to-outer should go in last. Any other suggestions are welcome.

Thanks