Rusted Air Box repair/replacement

[Jacobm99]

I took the driver's side fender off my 72 blazer to replace the lower A-pillar and noticed that the air box was rusted out (I think this is what it's called. It's the section where the debris that enters the cowl ends up).

1) Does anyone sell a remanufactured replacement (can't find anything in LMC or car & truck shop)?

2) If there is no replacement piece, is there anything wrong with fabbing up some sheetmetal and replacing it?

3) Why can't I just cut the bottom section off (I don't really see what purpose it serves; structural support maybe?)

4) Any suggestions on preveinting this from rusting going forward (I think I remember seeing a thread with a screen being mounted under the cowl- link? anything else?)?

Thanks in advance.

[raggedjim]

Jake, there is no aftermarket replacement panel. You could fab something up to replace the damage. As far as cutting and leaving it out, I think you would be safe as long as it is just the bottom part or pieces of the side.

I wouldn't leave out sections of the seam.

There are screens you can buy but I am going to make my own.

Good luck, Rg

[ronh72c10]

I had to make a similar repair for my burb. It wasn't really hard to make, but I did have access to a sheetmetal brake and shrinker/stretcher.

Some pics at metalmeet:

http://www.metalmeet.com/forum/showthread.php?t=3230

Ron

[LUV2XCLR8]

Very common area to rust out, as others said, some people make trap doors

[Jacobm99]

why a trap door? why not just a cut out?

[raggedjim]

From what I can tell (and I ain't the smartest guy) the cowl brings fresh air in from outside the engine compartment and into the floor vents. If you cut the bottom out and didn't close it up I think you would get a buttload of hot air coming from inside the engine compartment.

If I was going to cut it and leave it open I would seal up vents in the kickpanels... It would be bad to pass out from engine fumes runnning about 55...

I could be wrong, Rg

[Jacobm99]

I thought the same thing as I was writing that question last night. I was thinking of welding shut the vents anyway.

On the other hand, I drilled out some of the spot welds last night and it doesn't look like it would be too difficult to make a replacement piece (particularly since I doesn't need to be all that pretty being that it's covered by the fender).

[LUV2XCLR8]

Originally Posted by Jacobm99

why a trap door? why not just a cut out?

Yes, just cut it out and replace it all, some people make themselves a trap
door of sorts to clean it out every so often, especially if it's a outdoor rig.