Ok, I know this is a F-150 forum, but it's still a Ford.
I have a '65 falcon ranchero that leaks water into the cab between the left side hinge ( upper ) pillar and the underside of the cowel where they come together. This only happens when water is introduced through the cowel ( outside ). You can see it seeping in right where the two welded panels come together. Anybody had this with their falcon? There is no access to this area from outside.

 

You can buy a after market cowl cover. Had the same problem w/my 66 Stang. It's a clear plastic cover w/a weather tight rubber seal that goes around the outside. Then there's 3 clips with a type of wing nut that you would turn 180* to lock it on.

 

I'd love to see inside there and figure out where the water is getting through. There has to be some deteriorated seam sealer that's allowing the water through.

 

On my stang debris would accumulate inside the cowl, leave fragments, pine needles, etc, which would block the drain holes. The water would still drain but very slow. If there was a significant amount of rain then the drains could not keep up and the water would breech the actual tube that would allow the fresh air in resulting in H2O dripping on the floor.

 

Good chance its rusted out inside there and letting water in. Old stangs are notorious for the same thing.

 

Well, I got on a Forum that's mustang/falcon specific, and the prognosis is ugly. Rustout is a virtual certainty around the " tophat " that is the air intake for the vent, and the surrounding area. That means removing the cowel. That is an extremely invasive and time consuming job. I may yank the left fender and cut a hole on the side, and see if I can access enough to patch it with some sealant and call it a day. Maybe I'll sell it to Patch Adams. I should have done more research b-4 I put a billion in every other aspect of this rig.

 

There was a kit developed for 65-66 Mustangs. I would bet your Falcon would be the same. You are correct about the Vent openings rusting out around the trurned up edge. What you do is go up from underneath, thru the opening and clean the rust as good as possible. I used sand paper, a cordless drill, and a dremel. There is a plastic "tophat" that fits over the vent. You use a fiberglass kit to "glue" the top hat in place. Then I covered that with an insulator, roofing patch or tar. It is a painful chore as you are standing on your head and you have to reach up in a tight area and can't see what you are working on. I had to remove the seats to have enough room to lie in the floor. Hope this helps.

 

Thanks for the feedback. I have to find the repair part(s). I can't punt this close to the uprights.