Thanks for all the advice. I have too many projects to have this car tie up my heated garage space while I prowl the junkyards looking for a suitable donor.

What I did was make a template the matches the profile of the windshield opening so when I have time, I'll know what I'm looking for.

In the mean time I chipped out all the loose rust and wire brushed the opening. After treating it with rust remover and the phosphoric acid stuff, I fished a piece of 14 gauge wire inside the cowl, secured it with short soft wires and bondo-ed it in place. A few coats of bondo smoothed out the rough spots. After a coat of rust-oleum it looks pretty good. I'm confident with a new gasket and a little 3M Windo-Weld it will keep the water on the outside long enough.

Greg