I figure I'll kind of document the repair as it comes along. Every car probably suffers some form of this.

Got the hard sealer out from around the window. Looks like the glass has been out, and an attempt to reseal it was done, evidenced by the sticky sealer. Along with some very poor epoxy repair towards the lower sides. The pillars and top channel appear very good. The lower is basically shot all the way across with the worst in the center and the ends. I'll record some measurements as to how the windshield sits before pulling it.

So here is picture number 1,

I'll be tuning in.

I'm wondering what the best course of action would be? I have access to what appears to be a fairly intact cowl section. Do I attempt to cut away and replace the entire section, or do I just fab small sections and fit them in as I go across? Small diy sections might be far easier. Really, cosmetics need not apply here, just a good structure that can properly support and allow for a good seal.

Here's some shots of that cowl. I feel with this type, you can't really know the condition of the lower channel until the glass is out, or at least the surround sealer has been picked/broken out.

While it looks ok, there is some rust visible. Look at the little seam line just below the glass edge, if it looks kind of prominent, there might be rust in it bulging it open.

Anyone know the purpose of the small plastic pieces at the bottom corners? Held on by 2 Phillips screws. The screws and the remains of the tabs were all that were left of mine.

They could be stops. But there is also a rubber block in the same area. It's to the left of the circled area, above the little square metal tab.

Maybe intended to be some kind of deflector?

HI Mark

I was thinking the same as Paul, that they were supports for the windshield. I had a similar problem with my 66 Parisienne. I went with the piece meal since I wasn't able to find anything in better shape. At some point someone had filled the bottom with bondo the entire length but didn't drill the drain holes.

Luppy

Thanks for the shots Gary. Gives me a better perspective on how the sections overlap.

Yes, I'll probably just piece it in Carl. I should have the glass out today, so we'll have a better look see then.

Here are some shots of my 67 Impala which was in terrible shape.

Here is the full dash section that was brought out of the USA by my body shop.

Had to broken down into 3 sections to be properly welded in as the factory would have done.

This is the sad shape of the lower windshield area

Under Dash Shot 

Upper dash removed 

 Dash being spot welded into place 

 One of the process. 

Hope these shots will aid you in the work ahead 

Thanks to you Mark, I will now be cutting the full windshield channel out of my parts car as insurance! 

I think a full cowl change is beyond what I can tackle. So yes, it's going to be a piecemeal repair. I dont think it really needs to be pretty anyway. Just close enough that the glass fits right, preserved so it lasts, and watertight.

But if you have a clean parts channel, I would be definitely be cutting it out before scrapping the shell.

Now I just need to find some time to get at it. We all know how it goes...summers here! I'll now have all the time I need...right.

Carved the turkey:

I was looking for any metal on a windshield channel for a B body for my car on google. And surprisingly this came up! This is what mine looks like, except a lot worse on the drivers side, its actually gone/nothing there. And was curious how to shape it if nothing is there... 

Mark, how much do you charge?

Post some shots of your issues Mike, and maybe we all can suggest something of a plan. 

I just basically dug in and went at it, cut it all away, pieced and bridged it all together. Took about 4 days. Not pretty, but it's certainly solid and shouldn't leak.

But it was a milestone job, that felt really good to get out of the way.

This weekend when I get to the car, Ill take some pictures. Right now my windshield is in, but Ill take some pics when I get up there. 

Finally got around to taking some pictures of it... Any advice greatly appreciated. 

Looks like you are up against exactly the same condition Mike. A complete channel change would probably be a job for a pro shop, and would take some serious hours.

It's a situation here that basically you have to pull the glass, clean it all up to see what you have, cut it all out and piece it in. You can't be fussy here, it's a git er done kind of job. However, one important thing is to try to maintain the depth, angle and curve of the glass channel bed, along with the distance across to the dash structure. Get it wrong and you'll likely struggle with sealing and getting the reveal molding to sit right. Make a template when the glass is out, you can use to check it as you weld in. Start in the middle with your first brace to the dash structure and work out. Use zinc rich weld through primer on all your pieces both sides. I went with pieces no longer than 8 inches at a time and worked them into a slight curve as I went along. I blew through a ton of times, but just kept at it and filled them all with weld. Used seam sealer across it all but the sealing surface. 

Make sure ALL your glass is protected from grinder sparks.

My job left much to be desired, but should at least keep the water out.

Here's a simplified diagram of basically what was done,. I basically opened up the seam and inserted a vertical piece into the gap, then bridged across that piece to the dash structure.

Mike, if I had the time and a proper shop I'd certainly help you out here when I could. But I have a carport, and my time is spoken for for at least into the fall.

It's a bitch of a job, and to be truthful, if it wasn't for it being a labor of love on this car, I would not have bothered with the whole project.