Time for a quick update. Time in the garage is limited, as usual, but I have managed to get some work done. Most notably, I was able to check the clearance of the door after "finessing" it back into position, which I noted in my last update. I did use sheet metal screws to secure the inner cowl to the hinge pillar before checking the door fitment. Once I knew that the door fit correctly, I set about doing all of the welding. Because the inner cowl connects to the hinge pillar, floor, rocker panel, firewall and to the outer cowl, there was a considerable amount of welding. Of course, some of those required welds couldn't be done until after the outer cowl is replaced, but there was still a lot of welding to be done. I'm thankful to report that the welding that I could do now, is complete.
I was griping to Sweet about my dislike of the louvers on the outer cowl. I know that they serve a purpose for those that have the fresh air heater. However, my truck came with the recirculating heater and I plan to stick with that (before and after restoration pics attached). He convinced me not to do something rash, like weld the louvers shut, and to come up with a different solution. So, I set about looking for a kick panel vent (Chevrolet called it the "inner cowl" for our trucks, but most of the rest of the world knows it as a kick panel). I initially was interested in the fresh air vents used in early 1960's Chevy trucks. However, they all are priced at a steep premium, so I kept looking. What I settled on was a kick panel vent from a 1970's - 1980's Volvo. It was smaller than the opening, which I liked, as it would allow me to make an adapter that I could drill holes for that would exactly match both the Volvo vent and my truck. Because of the hinge on the vent being in the way, I had to make the adapter out of two halves and overlap them around the vent. I first made a template from the old fresh air heater delete plate that came in my truck and then fit the outline of the Volvo vent inside of the shape. I cut out the inside shape and what I was left with was the template for the adapter. All I did after that was to cut out the metal shapes, drill the holes and grind off the rough edges. I did a mock up of the completed assembly in the truck this morning (pic attached) and am happy with it! Once the weather clears, I'll take it out and apart, prep the unprimed piece for primer and when dry, paint both halves. Then I'll assemble the whole unit and set it aside until I'm done with the rest of the sheet metal work. It was a nice diversion and I think will ultimately be useful in bringing in more fresh air into the truck. The added benefit is that I did not permanently modify anything! If I ever change my mind, or a future owner wants, a fresh air heater can be added by simply unbolting the adapter and Volvo vent. Additionally, since those pesky louvers will still be exposed to the outside air, I plan on applying something to the inside cavity before closing it up with the new outer cowl. My initial thought is either bed liner or undercoating. In addition to providing corrosion protection, I'm thinking it might provide some level of sound deadening.
So, I know some are shaking their heads and wondering what in the world I'm thinking. That's ok! I think that I just look at the world a little differently. In the end, I think my truck will be fine and definitely, uniquely mine!
