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Old 12-04-2017, 05:55 PM   #1
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Fixing cowl plastic trim

The plastic trim piece between the windshield and the hood on my 2003 was popping up at the ends. You could push them down but they would pop up again. It looked a bit goofy.

I removed the small access cover and found that at the bottom of the "well" was a floor that was cracked and the 6mm nut with the built in washer was below the floor of the well......but it was not attached to the trim piece any more and not doing any good....so the trim piece/cowl would pop up at least and inch.

On the driver side I had enough material on the floor to make a big washer out of carbon fiber sheet that fit in the bottom on the well. I drilled a hole in the center and put in back on the stud and reinstalled the nut/washer.....Problem solved the new washer pulled the trim piece down in place. Everything tight and cowl trim down nice and low where it should be.

The passenger side was a bit more complex. Almost no "floor" on the edges to push down on. I made a new piece out to the same carbon fiber sheet material , but in this case I had to use JB weld to glue the new floor in place. I managed to pull the trim up enough to use masking tape to hold the carbon piece in place and to for a mold so the JB weld would not escape. I mixed up a batch of JB and glued everything in place. After drying about an hour I drilled a new hole in the center and put the nut/washer back on along with another carbon fiber washer just to be safe.

Now the cowl trim look like it fits again.

You can get a new piece from our sponsor for something like $156. If this does not hold I will opt for that.

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Last edited by boxfix; 12-07-2017 at 04:27 PM.
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Old 12-04-2017, 06:16 PM   #2
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Well done sir. Any before/after pics available?
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Old 12-04-2017, 06:44 PM   #3
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Well done sir. Any before/after pics available?
I will try to get some tomorrow.
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Old 12-04-2017, 07:38 PM   #4
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Common problem, nice solution
Pics or it ain't real LOL
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Old 12-05-2017, 12:33 PM   #5
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Passenger side of cowl with cracked hold down.




JB weld and carbon pieces bonded into floor.
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Old 12-05-2017, 12:36 PM   #6
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this the carbon fiber "washer" I made.

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Old 12-05-2017, 12:39 PM   #7
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Here are some photos of what I did to fix the cowl that was no longer attached at the ends of the plastic cowl.

I made "washers" from carbon fiber sheet material. The washer is the same shape as the bottom of the well that attaches the plastic with a stud and a nut/washer. If you have any material horizontal material that is still attached to the wall this washer should hold it down.

I you have nothing at the bottom, you can JB Weld the "washer" in place as I did on one side.

I am thinking of maybe making up a few sets of washers. PM me if interested.


Here is the washer in place. The nut with steel washer attached [OEM part] is then intalled and tightened with a 10mm socket.




This is the finished look of the cowl trim after repair.



Sorry for the multiple posts.....I had to relearn posting photos.
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Last edited by boxfix; 12-05-2017 at 12:47 PM.
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Old 12-05-2017, 03:39 PM   #8
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I need to do this


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Old 12-06-2017, 02:51 PM   #9
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I replaced mine. I went to the dealer and ordered it ~$60 if I remember. At that price I don't mind replacing every 15 or so years. Hardest part was getting drivers wiper arm off - need a really short wiper arm puller which I didn't have. The dealer popped mine off and then put it back on lightly until I could get home and swap out the part.
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Old 12-06-2017, 06:09 PM   #10
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I replaced mine. I went to the dealer and ordered it ~$60 if I remember. At that price I don't mind replacing every 15 or so years. Hardest part was getting drivers wiper arm off - need a really short wiper arm puller which I didn't have. The dealer popped mine off and then put it back on lightly until I could get home and swap out the part.
You got a deal. Pelican wants 145.50 for Windshield Cowl Cover Part #: 996-572-563-06-01C-M100

Sierra Madre is asking $173.86

For those prices I will see how long my fix lasts!!!
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Old 12-07-2017, 07:32 AM   #11
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Thanks for this.
With wet weather coming up, this is something that I need to deal with also.
If I can avoid buying a new one and spray painting the old one black and using your trick, that would be great.
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Old 12-07-2017, 09:30 AM   #12
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I have an extra that I bought recently. Little sunfaded but I only needed one of the bolt cover pieces and wound up with the entire thing. Anyone decide they'd rather replace than repair, message me and we can work something out.
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Old 12-07-2017, 10:24 AM   #13
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Originally Posted by boxfix View Post
You got a deal. Pelican wants 145.50 for Windshield Cowl Cover Part #: 996-572-563-06-01C-M100

Sierra Madre is asking $173.86

For those prices I will see how long my fix lasts!!!
$117 from sunset.
still. double of what it used to cost 4-5 years ago.
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Old 12-07-2017, 04:30 PM   #14
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Thanks for this.
With wet weather coming up, this is something that I need to deal with also.
If I can avoid buying a new one and spray painting the old one black and using your trick, that would be great.
To get the grey out, I coated mine in silicon fluid, and it looks good for now.

I may yet take it out and paint it with Rustoleum 7777 satin black. I have done this on my Saab Aero and it has looked good for years.
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Old 12-07-2017, 05:01 PM   #15
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To get the grey out, I coated mine in silicon fluid, and it looks good for now. ...
Thinned linseed oil work well too for black plastic pieces that are weathered.

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