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Discussion Starter #1 (Edited)
The problem is the cowl louver gets torn off by someone who didn't know to reveal the screws at the corners and they yank the plastic off the car....anyway, I wanted to fix mine....on both sides.



Taking it off and turning it over showed there was too much plastic missing to do a plastic weld to restore the attach points.





So I needed to make a repair part that would fit over the broken plastic and screw to what was left....I would make an aluminum part that was about .030" thick. I wanted it to match the angle of the bottom close enough to give clearance to the screws.





Fits like this:



Holes marked where there is plenty of plastic....





Threw some black satin paint for the heck of it




I pushed the mounting tab down a little to make up for the extra .030" in length of the repair...just push down on the screw, it will give easily....




Reassemble.





Done.


 

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Discussion Starter #5
I designed the repair part and then made it in my lathe and mill out of aluminum from Dominion Recycling in Hampton Va. ($1.75 per Lb.) I made a spare set of these repair parts while I was at it ...my other car doesn't need it ....
 

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Discussion Starter #8 (Edited)
OK, that's fine if it doesn't work out.

I did notice the need for a weep hole at the lowest point in the repair part so rain water can fall out....took the paint off while it was apart.

 

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Discussion Starter #9
nammerbboi and rice247,

I made only 2 parts extra, you both would like to fix this on your cars, I will send each of you one, free and with free shipping to your door, that is the best I can do. PM me and I will get it out to you.
 

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nammerbboi and rice247,

I made only 2 parts extra, you both would like to fix this on your cars, I will send each of you one, free and with free shipping to your door, that is the best I can do. PM me and I will get it out to you.
Prolly don't have spare ones do ya? I would like to fix mine as well as I have the same issue. I also can't source one locally in better condition than mine :(
 

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Discussion Starter #16
Re-making cowl repair parts

How about this? I will get the specs together and make a jpg of the drawing ...you can have some friend with access to a 3D printer make you a couple?
It won't be as strong as a machined aluminum part but it really should be fine if
it can handle the heat of the summer that is....

I hope I have this saved somewhere, I think I do ...
 

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Discussion Starter #17
Drawing of Cowl Repair Part

Here is the repair part...if machining ....it is good as is...if 3D printing in plastic, make the outside dimensions .030" larger so it will print well and have more strength....don't forget the weep hole shown in the pictures.


 
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