Cowl Rust Cause?

[Synchro909]

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Originally Posted by wrndln

The problem is that there is a triangle shaped gusset to strengthen the cowl panel on the inside of the cowl. There is a gap between the gusset and the cowl exterior sheetmetal. Salt, water and who knows what else accumulates in the approximate 1/8" space between the gusset and cowl panel and causes rust problems. I have repaired three pair of rusted out cowl on 28 and 29 vehicles. You are definitely correct that this is a problem spot for 28/29 model A's due to years of use on questionable roads. I cut out the exterior panel in the shape of a triangle and butt weld in a patch of the same gauge. The repairs work well - see attached pictures.
Rusty Nelson

Is that patch (2nd picture) overlapping the original metal??? If so, what do you do to stop rust getting into the overlap?