This is the driver's side of the cowl. Another Swiss cheese mess. The bracket on the left is a reinforcement plate for where the windshield attaches. I don't want it or need it, so used the air chisel to pop it off. It was only held in place towards the bottom.
A close-up of the holes. Eleven in total.
Sanded back to prep for welding. Through most of the holes, you can see a plate behind it.
Look at all the off-gassing flux.
Making some headway. A few of the holes needed discs for plugs. The holes on the left (all three) will remain, two for the windshield pivot point and one that I think can be used for an antenna, a fluid line, or something of that sort. I won't be using it for any of those, so I'll likely plug it with a firewall grommet.
This shot is just a reminder of the bondo I'm starting with.
I went to town, blowing through about twenty discs of 180 grit to do the side, which I think is more a commentary on the lousy quality of sanding discs than anything else. I'm very happy with how the bondo helped eliminate seams for my patch panels and a few of the ripples that were already in the tub.
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