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How do I fix the rust on the cowl / firewall seam I will be replacing the firewall not sure what to do on the cowl seam is there and patch panels available or do I need to try and make some ?
I could be wrong but I haven't seen patch panels available for that. Probably going to have to make a patch panel or find someone with a parts truck you can cut it out of.
I have not seen anything re popped for the cab except a complete floor, not going to help you since it stops at the toe box and cowl corners, which may be useful to you. I have not seen a firewall offered for the 67-72 which is why I got another cab when I was posed with the same issue you have. You find the seem has rust through all the way up under the dash, mine did.
Like someone posted, it is likely you will uncover more rot.
I fixed up a cab that most people would have scrapped. It is like peeling an onion. I would cut out a manageable portion and make a piece to fit and then cut some more and repeat the process. Doing this allowed me to fix from the inside out once all the rusted out areas were gone and have pieces that would be a close fit. If you know how to weld this can be a fun project. I had no experience doing metal work before. I used body working hammers, a section of rail and a good vise as an anvil and a HF shrinker/stretcher. Go for it.
I did something similar to what T Henry wrote, cut out a piece at a time, make s piece and weld it in place, rinse and repeat… depending on what your end goal is, it’s a good place to practice, it’s not going to be very visible, so it just needs to be solid… I’d say go for it as well
Or maybe find a sheet metal shop and see if they can make/fold a piece that looks more like the cross section of a T or railroad track. Then you could replace sections and never have a seam for water to get in. (I hope I made sense)
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