Kevin; I can see what you did from your pictures, please enlighten me on how you were able to define the shape you wanted to get for the inner-to-outer cowl piece. For example, did you use the curve that is stamped into the outer cowl piece to define the side view of the curve? How did you scribe that shape you wanted onto the side of the inner cowl (kick panel). If I can see it, I know I can make it happen. I know that the bottom of the inner-to-outer cowl piece has to line up with the holes in the rocker panel.
One technique may be to just cut the inner-to-outer cowl piece in half, then fit the bottom to the rocker panel and then fit the top to the top of the outer cowl and then make the curve work as you form the two pieces back together.
Please se enclosed picture. I convinced myself that the curve in the outer cowl piece fit my fender correctly, so I thought I might make that curve the defining parameter for shaping the inner-to outer cowl curve. Thanks