"Rocky" - 1981 F250 Restoration

[Gary Lewis]

I agree. Actually I went a little overboard. I noticed Jegs has a right-angle seat belt mounting bracket kit. It's way too expensive at $14 (each) for what amounts to a piece of 1x2 angle, two holes, and a bolt but... I must be exactly the kind of sucker they make these for because the time savings was worth it to me. Once again, setting the seats aside at "almost done" for another project while I wait for the parts to arrive...

It's supposed to be warmer today but it isn't there yet. I think I may try to tackle two small projects: upgrading the dome light to the dome/map light unit, and hacking together my reverse-sensor-switch wire somehow so I can close the transmission cover and get the carpet laid down. The one thing holding me back is I'm noticing some water on the floor of the driver's side. I think it's dripping in as the snow melts through the hole I used to add the wire loom for the door, so I guess I need to seal that better. It may be time to break out the Lexel...

I think you made the right choice. You can't buy time, but buying parts that save time is sort buying time.

Good luck on the other projects. And I hope you get the leak sealed easily.

[taskswap]

I think you made the right choice. You can't buy time, but buying parts that save time is sort buying time.

Good luck on the other projects. And I hope you get the leak sealed easily.

Welp. It was the wiper motor after all (wipers not parking). I put a new switch in first, and that didn't help, but I don't regret it. My old switch was so fragile it fell apart in my hands as I pulled the plug on it to install the intermittent control module. Today I gathered my courage, made sure there was beer in the fridge, and decided to tackle the wiper motor.

Man, getting that cowl cover off is a PAIN. I can see why some people remove their whole hood to do it. Is there any specific "trick" to reinstalling it without scraping it underneath the hood (other than removing the hood)? I was thinking of painting it while it's off and hate to ruin it when I reinstall it...

Anyway I got that all removed and discovered basically a household-rain-gutter full of pine needles, decayed leaves and other wet junk in the channel underneath. It's tempting to try to add some metal screening on the bottom side of the cowl before I reinstall it - anybody ever try that?

I think I also figured out how water was getting into my driver's side floor pan as the snow melted. Looking down the A pillar channel, I can clearly see the back end of the drivers left-leg air vent peeking out into that space. The air vent used to have a foam gasket but I figured it was just to provide a better air/sound seal. I don't think it would have done much for water, so I didn't try to replace it. But maybe I need to add some weatherstripping. Or maybe I just need to find a way to "delete" the vents entirely. IMO they're just asking for trouble in a lot of ways, and I'm still set on making this ARA A/C system work.

Installing the wiper motor went mostly OK. The reviews on this unit all said "drop in replacement for my truck!" which must be mostly fake because it sure wasn't a drop-in. The pin on the end of the armature/crank that goes into the two wiper arms wasn't the right length. There's no way it would work as-is. Fortunately I still had my old motor and the motor spindle was basically the same size/shape, so I was able to transfer over my old armature. And now my wipers park!

The intermittent still doesn't work though. On Gary's advice I disassembled my control unit to look for cold/broken solder joints and it all looked pretty good, but I could have missed something or just have a bad unit (it was an eBay find). Intermittent wipers aren't actually a huge deal to me so I'm going to set this task aside and come back to it later, but at some point I'll probably replace the controller or at least re-inspect it.

As usual, now waiting for more parts!

That beer helped

[Gary Lewis]

Welp. It was the wiper motor after all (wipers not parking). I put a new switch in first, and that didn't help, but I don't regret it. My old switch was so fragile it fell apart in my hands as I pulled the plug on it to install the intermittent control module. Today I gathered my courage, made sure there was beer in the fridge, and decided to tackle the wiper motor.

Man, getting that cowl cover off is a PAIN. I can see why some people remove their whole hood to do it. Is there any specific "trick" to reinstalling it without scraping it underneath the hood (other than removing the hood)? I was thinking of painting it while it's off and hate to ruin it when I reinstall it...

Anyway I got that all removed and discovered basically a household-rain-gutter full of pine needles, decayed leaves and other wet junk in the channel underneath. It's tempting to try to add some metal screening on the bottom side of the cowl before I reinstall it - anybody ever try that?

I think I also figured out how water was getting into my driver's side floor pan as the snow melted. Looking down the A pillar channel, I can clearly see the back end of the drivers left-leg air vent peeking out into that space. The air vent used to have a foam gasket but I figured it was just to provide a better air/sound seal. I don't think it would have done much for water, so I didn't try to replace it. But maybe I need to add some weatherstripping. Or maybe I just need to find a way to "delete" the vents entirely. IMO they're just asking for trouble in a lot of ways, and I'm still set on making this ARA A/C system work.

Installing the wiper motor went mostly OK. The reviews on this unit all said "drop in replacement for my truck!" which must be mostly fake because it sure wasn't a drop-in. The pin on the end of the armature/crank that goes into the two wiper arms wasn't the right length. There's no way it would work as-is. Fortunately I still had my old motor and the motor spindle was basically the same size/shape, so I was able to transfer over my old armature. And now my wipers park!

The intermittent still doesn't work though. On Gary's advice I disassembled my control unit to look for cold/broken solder joints and it all looked pretty good, but I could have missed something or just have a bad unit (it was an eBay find). Intermittent wipers aren't actually a huge deal to me so I'm going to set this task aside and come back to it later, but at some point I'll probably replace the controller or at least re-inspect it.

As usual, now waiting for more parts!

That beer helped

Peeling the onion. Peel, cry, peel, cry, but soon you'll have a Bloomin' Onion!

Glad you got the wipers going. Not sure what to say about the intermittent part. Other than "good luck".

As for the vents, I'd put weatherstripping on them. If you RTV the you'll never get them off - at least w/o breaking them.

But you might want to keep the vents for air flow when you don't need the A/C. I added them to Big Blue and really like them.

[grumpin]

Welp. It was the wiper motor after all (wipers not parking). I put a new switch in first, and that didn't help, but I don't regret it. My old switch was so fragile it fell apart in my hands as I pulled the plug on it to install the intermittent control module. Today I gathered my courage, made sure there was beer in the fridge, and decided to tackle the wiper motor.

Man, getting that cowl cover off is a PAIN. I can see why some people remove their whole hood to do it. Is there any specific "trick" to reinstalling it without scraping it underneath the hood (other than removing the hood)? I was thinking of painting it while it's off and hate to ruin it when I reinstall it...

Anyway I got that all removed and discovered basically a household-rain-gutter full of pine needles, decayed leaves and other wet junk in the channel underneath. It's tempting to try to add some metal screening on the bottom side of the cowl before I reinstall it - anybody ever try that?

I think I also figured out how water was getting into my driver's side floor pan as the snow melted. Looking down the A pillar channel, I can clearly see the back end of the drivers left-leg air vent peeking out into that space. The air vent used to have a foam gasket but I figured it was just to provide a better air/sound seal. I don't think it would have done much for water, so I didn't try to replace it. But maybe I need to add some weatherstripping. Or maybe I just need to find a way to "delete" the vents entirely. IMO they're just asking for trouble in a lot of ways, and I'm still set on making this ARA A/C system work.

Installing the wiper motor went mostly OK. The reviews on this unit all said "drop in replacement for my truck!" which must be mostly fake because it sure wasn't a drop-in. The pin on the end of the armature/crank that goes into the two wiper arms wasn't the right length. There's no way it would work as-is. Fortunately I still had my old motor and the motor spindle was basically the same size/shape, so I was able to transfer over my old armature. And now my wipers park!

The intermittent still doesn't work though. On Gary's advice I disassembled my control unit to look for cold/broken solder joints and it all looked pretty good, but I could have missed something or just have a bad unit (it was an eBay find). Intermittent wipers aren't actually a huge deal to me so I'm going to set this task aside and come back to it later, but at some point I'll probably replace the controller or at least re-inspect it.

As usual, now waiting for more parts!

That beer helped

Yes I believe some have put screens under the cowl openings. And some and I’m pretty sure Gary did, put the later style cowls on with the smaller holes like my 92 Bronco.

The cowl is hard without removing the hood, I got mine loose and lifted a side at a time to clean it out. Then found a bunch in the panels where the vents are. I have A/C so no vents, but panels. The debris was about level with the lower part of the panel.

Also found a lot when replacing the blower motor. All around the resistor.

I think next time hopefully this summer, I’m going to try and blow the debris down and get it through the panels.

[FuzzFace2]

Then found a bunch in the panels where the vents are. I have A/C so no vents, but panels. The debris was about level with the lower part of the panel.

Also found a lot when replacing the blower motor. All around the resistor.

I think next time hopefully this summer, I’m going to try and blow the debris down and get it through the panels.

Yes if you have water coming in at that panel then you have dirt / leaves blocking the drain that is below that point.

Pull off the kick panels and remove the 4 screws holding the metal block off panel in place and clean it out.

Water should flow from the cowl down the pillars on either side and out the "duck bill" seal and out the bottom of the fenders.

Now you may find after cleaning everything that the seam sealer is all dried up and failing so once dry that will need to be addressed.

Some have used Flex Seal put a plastic nozzle with plastic straw so they can put the sealer where it needs to be. It comes in clear / white and think black maybe other colors?

Because I had the nose off my truck I was able to use seam sealer after I removed the old bad sealer and reseal it with 2 coats.

Dave ----

ps: if you can find good vent kick panels you can leave the metal panels off, install the vent panels and have flow through air.

My truck did not have factory AC so it had the vents. When I added factory AC I left the vents as it was going to be a bit before I could get the AC system up & running. I have had issues with the system holding a charge so the vents come in handy LOL

 

[Gary Lewis]

Then found a bunch in the panels where the vents are. I have A/C so no vents, but panels. The debris was about level with the lower part of the panel.

Also found a lot when replacing the blower motor. All around the resistor.

I think next time hopefully this summer, I’m going to try and blow the debris down and get it through the panels.

Yes if you have water coming in at that panel then you have dirt / leaves blocking the drain that is below that point.

Pull off the kick panels and remove the 4 screws holding the metal block off panel in place and clean it out.

Water should flow from the cowl down the pillars on either side and out the "duck bill" seal and out the bottom of the fenders.

Now you may find after cleaning everything that the seam sealer is all dried up and failing so once dry that will need to be addressed.

Some have used Flex Seal put a plastic nozzle with plastic straw so they can put the sealer where it needs to be. It comes in clear / white and think black maybe other colors?

Because I had the nose off my truck I was able to use seam sealer after I removed the old bad sealer and reseal it with 2 coats.

Dave ----

ps: if you can find good vent kick panels you can leave the metal panels off, install the vent panels and have flow through air.

My truck did not have factory AC so it had the vents. When I added factory AC I left the vents as it was going to be a bit before I could get the AC system up & running. I have had issues with the system holding a charge so the vents come in handy LOL

Yes, Big Blue has the 1987 and later pin cushion cowl, and it is keeping that area free of debris. But I'm going back with the original cowl on Dad's truck and will put plastic mesh on the back side.

As for getting the cowl on/off without damaging it, I loosened the hood bolts and slid the hood to the farthest forward position and then snugged them down. That got me close on clearance, but it didn't get as much as I wanted. So I then left the bolts loose so the hood would angle a bit on the hinge to get even more clearance. But in that case you can't open the hood much or it'll slide back down, and you have to prop it open with something at the front end. And make sure to mark the position of the hinge before you do that.

However, all of that is a major pain and chipping the paint is a real possibility. I think if I had new paint I'd protect it with tape. Or pull the hood completely off.

[taskswap]

Yes, Big Blue has the 1987 and later pin cushion cowl, and it is keeping that area free of debris. But I'm going back with the original cowl on Dad's truck and will put plastic mesh on the back side.

As for getting the cowl on/off without damaging it, I loosened the hood bolts and slid the hood to the farthest forward position and then snugged them down. That got me close on clearance, but it didn't get as much as I wanted. So I then left the bolts loose so the hood would angle a bit on the hinge to get even more clearance. But in that case you can't open the hood much or it'll slide back down, and you have to prop it open with something at the front end. And make sure to mark the position of the hinge before you do that.

However, all of that is a major pain and chipping the paint is a real possibility. I think if I had new paint I'd protect it with tape. Or pull the hood completely off.

Thanks, guys. Good input here. Any opinions how you might attach screening to the underside of the cowl? I want it to stay put but I don't want to do rivets (nothing visible from the top) or adhesive (I doubt it'd stay put). I thought about maybe JB-welding some thing right-angle brackets all around the vents on the underside, so I could "pop in" a piece of metal screening. Not sure that would hold but I could try it...

[Gary Lewis]

Thanks, guys. Good input here. Any opinions how you might attach screening to the underside of the cowl? I want it to stay put but I don't want to do rivets (nothing visible from the top) or adhesive (I doubt it'd stay put). I thought about maybe JB-welding some thing right-angle brackets all around the vents on the underside, so I could "pop in" a piece of metal screening. Not sure that would hold but I could try it...

My paint/body man said we'll use an adhesive, but I didn't ask exactly how.

I think you want it up against the bottom of the cowl so stuff can't get between the screen and the cowl. And if you just glue it to the edges I'm afraid it'll droop. I wonder if you can squeeze adhesive through the screen and into the back side of the louvers?

Or, maybe JB Weld studs into the back side of the louvers and push the screen down over them and put nuts and washers on the studs to hold the screen up. And you could put a "spreader" on each stud and hide it under the louver.

[taskswap]

My paint/body man said we'll use an adhesive, but I didn't ask exactly how.

I think you want it up against the bottom of the cowl so stuff can't get between the screen and the cowl. And if you just glue it to the edges I'm afraid it'll droop. I wonder if you can squeeze adhesive through the screen and into the back side of the louvers?

Or, maybe JB Weld studs into the back side of the louvers and push the screen down over them and put nuts and washers on the studs to hold the screen up. And you could put a "spreader" on each stud and hide it under the louver.

I know it seems a little crazy but I like the idea of some type of studs... but also don't love the long-term life of adhesives on the underside of there, I just don't have a lot of confidence it will stay put. So I'm thinking of soldering something on. McMaster has these "elevator bolts" at $8 for a 25pk in the smaller sizes:

I think I can get away with silver-soldering them on the underside of the cowl without warping it (I'm not worried about the paint because I'm going to strip and repaint it anyway). If I do that I think I could put metal screening under the cowl vents and fasten them to these studs with washers and lock nuts. I'll have to measure the clearance but I think if I'm careful I can get away with it.

That's a project for another day though. Right now I'm gathering my courage to do some work in the cold. I pulled my shifter cane out for what I hope is the last time so I could fix my reverse switch plug. Today I need to reinstall that and make the final hole in the carpet where the shifter boot goes so I can install that. Fingers crossed.

[Gary Lewis]

I know it seems a little crazy but I like the idea of some type of studs... but also don't love the long-term life of adhesives on the underside of there, I just don't have a lot of confidence it will stay put. So I'm thinking of soldering something on. McMaster has these "elevator bolts" at $8 for a 25pk in the smaller sizes:

I think I can get away with silver-soldering them on the underside of the cowl without warping it (I'm not worried about the paint because I'm going to strip and repaint it anyway). If I do that I think I could put metal screening under the cowl vents and fasten them to these studs with washers and lock nuts. I'll have to measure the clearance but I think if I'm careful I can get away with it.

That's a project for another day though. Right now I'm gathering my courage to do some work in the cold. I pulled my shifter cane out for what I hope is the last time so I could fix my reverse switch plug. Today I need to reinstall that and make the final hole in the carpet where the shifter boot goes so I can install that. Fingers crossed.

You are braver than I am with the silver soldering. But why not put a later model "pin cushion" cowl on? It'll solve the problem without a screen.

However, if you stay with the Bullnose cowl I wouldn't use large washers as I think they'll be seen from above. I'd make long "spreader bars" that are about the same width of the metal of the cowl so they can hide under the cowl.