I have finally got the electrical for the lights sorted out and am moving on. Actually dose anyone have a pattern for the rear light gasket I could use to make my own gasket from? ( 73 Spider)

No surprise that the wipers don't work in a car that has been sitting for 25-30 years. Removed the cowl and wiper assembly. Removed the wiper assembly from the cowl and found it completely seized. It wouldn't budge even tapping with a hammer. Pretty easy to use rust release, scrapper and wire brush over 2 days and it is working fine. You need to soak it in the rust release generously over multiple times to start to get a little play then work the assembly until you get the full range of motion. The motor connecting arm needs to be removed to do this. Bench tested the motor and it work .

This is the condition I found under the cowl.




I cleaned it and got this.



I used a scrapper and then a wire wheel on a drill. There is a layer of black hard tar like substance that is covering the metal. I know this is some kind of rust protection material from 30 years ago. Question is should I remove it or just paint over it with anti rust paint?

Plenty on threads on this material in the cowl area. I think the general consensus is that leaving the old tar in there is not a great idea, as most of it is not well adhered to the base metal and will just trap water. I removed all mine with one of those oscillating tools and a scraper blade. Cleaned up the metal and put POR15 on it.
Kirk

Thank you for your reply. Ok...looks like I will have to get one of those tools. Is it like a motorized chisel? I am sure I will encounter this when I replace the carpet on the floor. You are right about doing the total job and not take short cuts.

I used a putty knife and a hammer the black tar comes up pretty easy.

Update and questions on this PITA job. Tried to use putty knife and hammer but bent the putty knife. Used a regular chisel and was much better but painfully slow. Borrowed a power chisel and much easier to remove tar but took time and left some thin traces of tar. I have never done body work and could use suggestions. I have been using a drill with a dense like brush on the end to remove the paint and remaining tar. Very difficult to get into the nooks and crannies to prepare for POR 15. Any suggestions.





By the way my car was originally yellow.

I also want to repaint the black plastic vents and replace the washer hose. Can anyone tell me how to remove the plastic vents without braking them and the hose diameter I need.

I think the plastic vents are held in by 2 or 3 rubber knobs screwed into the central area of the cowl; while the clips holding onto the the washer hose slide on & lock into place in a hole. Looking at your picture the clip would slide to the left. The rubber knob is in the upper left corner of the pic. Twist it ccw until loose. Be extra careful as the plastic is extremely brittle. You might have to play with it a little to get it out. There are two separate vent pieces with a clip in the center connecting them, at least on mine there was. I pull them out together through one side.

I have completed this job. I did not remove the plastic grills but gave them a gentle cleaning. I was too nervous they would break and be a problem to replace. I did remove and paint the black hold down brackets as well as the cowl. Also replaced the windshield washer motor and hoses. Here are some pictures of using POR 15. There are lots of instruction and video's available on this site and on the net.. Used plumbers putty in the corners and around the hood supports.



Cleaner/degreaser



Metal prep



POR15



Paint over POR15



Plumbers putty in corner of windshield and around hood support posts



Cowl back in place

I saw in another thread about the removal of the tar. Yes this is a real PITA!. The tar not only provides rust proofing but also noise and vibration deadening. If I have a problem or a good solution comes up I will simply remove the cowl and apply what ever application will work but for know I will live with it being painted.

Nice work!

How does one remove the cowl? Is it as easy as just removing the hex bolts exposed when you open the hood or do you have to remove the wiper arms etc first? My vents under the cowl are misaligned and I'd like to fix it...they're totally crooked and don't cover the last half inch on the driver side. Makes me nuts

Thanks Arik. You do great work on your car.

First tip take pictures. Second tip have a friend to lend a hand. Third cover your fenders ..I used towels so they don't get scratched. Lastly have a container for the screws and bits!

This is a straight forward job for a lot of the people on this form and there are good threads on it. Yes remove the wipers; black plastic stem covers with o ring and octagonal chrome washer. Remove the screws and pull the cowl back from under the windshield. You need to be on the passenger side to disconnect the wiper motor and washer hose. Lay your cowl on a planned surface and there you are. You should note I did not remove the plastic vents. On mine there are 3 screw downs on springs and well as 2 black spring clips holding it down.

You can evaluate were to go from there. I would definitely grease the moving joints in the wiper mechanism.

Enjoy the task and hope you have good results. By the way my car makes me nuts as well at least accordingly to my wife!