As of 072323, we have the driver side, outer side cowl and inner side cowl "Cleeco'd" in with pretty good fit. Adhering to the FAM for Ref #'s 1, 2, 3 and 6, with one exception, the height from the 0 line for hood hinge bottom hole (Ref # 6). The spec says it should be a little lower than I have it, but examining the passenger side and recalling what it looked like on the driver side from the original metal, I am leaving it where it is, hoping if it is off a little bit north-and-south, that there is enough available adjustment in the hood hinges to accommodate. We also compared the door measurements to the opening between the hinge pillar and the lock pillar in a few places. I made sure that I had at least 1/4 inch wider between the pillars than the door itself measured at the same places, allowing for at least 1/8 inch gap all the way around. in some of the pictures, you can see that I cut an oak stick 34.4 inches in length and it fit fine between the bottom of the hinge pillar and the bottom of the lock pillar. The door bottom measured 34.15 inches in width.
Now for the part where I need some wisdom from the crew (YOU). I am looking for advice on how to approach the cowl side rail. It is obvious to me that it needs major surgery if it to fit as well as the original. Hell, it does not even match the "curve" of the replacement outer cowl piece to which it is supposed to be welded, even though I sourced both pieces from the same vendor. For example, do I make it fit the outer cowl piece first, and then adapt it to the new inner cowl piece (the kick panel if you will) as a unit (outer cowl and cowl side rail)... ??
Many thanks to all for caring to help me along this journey to have a zero rust cab from which to build upon.
