Been there done that. Sliced and diced the inner-to-outer to match up with the rest of the pieces. Cut some slots and move the material around to fit, adding more material in the gaps produced. What you're seeing is typical. I only have a couple pictures that really shows the work I did to make it fit in the area you're having issues with. You can see where I sliced back along the corners and bent the metal into shape. Mine was actually too tall, so I didn't have to add material there, but did on the lower end to make it match the curvature of the inner cowl panel better and make the notches on the inner side match with the reinforcing beads on the inner cowl. At best, the available inner to outer cowl pieces are a source of raw material to make one that fits.
Kevin 1951 Chevy 3100 work truck Follow this saga in Project Journal Photos 1929 Ford pickup restored from the ground up. | 1929 Ford Special Coupe (First car) Busting rust since the mid-60's If you're smart enough to take it apart, you darn well better be smart enough to put it back together.
