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I've just started killing the cancer on my '65 F-250 and I noticed a rather large hole behind the dash that I can't seem to reach with any of my power tools. The only way that I can see to take off the dash is to drill out the welds to remove it. Please tell me that there is another way that doesn't involve trying to drill out everything.
I read this yester day and was wondering where the hole could be that he can't reach it! I have a 66 in my garage today, that has all the dash components removed and I honestly believe I could hide up in there and I weigh 250 Lbs? Un bolting/screwing the cluster, heater, glove box, wiring, Radio, column support and colums is a heck of a lot easier than cutting out a dash. If the hole is on the outside end of the cowel, it would be easier to remove the fender and make a "window" to work through and when the rust hole is repaired close the window and put the fender back on.
the hole is behind the instrument cluster and up near the top of the wall. it's about 2 fists big, and i can't see it from the engine compartment, but i can see it from the slots in front of the windshield. there is a brace behind my instrument pannel that i can't fit my drill or grinder behind (don't have any air tools). I may try cutting out that brace and rewelding it later instead of the whole dash. thank you all for your suggestions.
Now we are getting somewhere. Remove the brake/clutch pedal support and the wiper transmission arm. Using a 1/8 th inch drill remove the spot welds on the sheet metal brace. Repair the rust hole by welding in a patch, then re-install the brace by welding shut the original removal holes. Rust in this location is highly unusual and you may want to carefully evaluate the overall condition of this cab. Sometimes it is better to simply replace a rusty cab.