A quick update. Still plugging along on passenger side sheet metal. I ended up having to make a patch that covered a part of the firewall and toeboard. It now covers one of the factory holes for the fresh air heater tubes. The factory sheet metal that has that opening is preserved in the cab, so that a future owner can open it up if desired. I'm sticking with my recirculating heater, so it isn't needed. The factory sheet metal also preserves the holes for the screws that attach the filler panels. This metal wasn't good enough for structural purposes, so the patch that I made covers that area and more. You can see in the pic that I used quite a few plug welds, plus edge welds to hold it all together. I'm sure it will be cringe inducing for some, but that's ok. It appears to be solid and does what I needed. I've included several pics. The first is a 3/4 profile showing all of the cowl pieces that I replaced. I used the FAM for locating the plug welds for all of the parts. The inner-to-outer cowl piece was very difficult to weld into place, as many of those weld locations were right up against the inner edge. It required a longer than normal stick out to reach the inner cowl metal and was hard to manage. In retrospect, it would have been easier to weld it from inside the cab. We'll see how I handle it on the driver side. The second pic shows the outer cowl and the body filler work, so far. It's really close, but not quite there. The final pic shows looking down the cowl. If you look closely, you can see a small flat spot in the body filler area. That was a low spot that was revealed with some sanding today. It's currently with another thin coat of filler that is curing. I'll look at it tomorrow. Hopefully, that's the last of it.
