fixing rusted windshield channel

[dvdswan]

So I knew I had a small issue already on the driver's lower windshield area when I bought the truck.   I picked up a new/used windshield from the local yard a while back and hoped today to just swap it and be done until I was going to restore the truck.   Well, as luck would have it, it was worse than I thought.  Not atrocious but bad. 

I know I can fix it but was wondering how far should I cut out the rust.  I know you want to get all of it, but as far as the replacement piece (I've already spotted a donor piece at the local yard in great shape) should I get the complete "A" pillar and cowl?  should I get the area around the door hinge area as well?

It looks as if the cancer is just in the immediate area of the image with surface rust on the driver's upper corner and passenger lower corner.

[Funkatation]

I'd like to see an answer too. Mine has similar rust.

[RAD77C10]

On the upper spot grind it, if there any rust left brush with some acid. Then clean, metal eching primer, POR15 sealer. In the lower corners I would cut out just what is bad, cut your replacement parts the same size & braze or mig weld. Grind it smooth, primer, & POR15.

[enaberif]

That much damage I'd be looking at a new cab. That is toooooooo much work.

[roundhouse]

Clean it up really good and take some more pics




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[nucknoel89]

Mine was way worse and I did a decent job fixing it. I don't have a pic of the end result, but I just cut out the cancerous parts and did my best to make patch pieces and spread some filler to compensate for the rest. It doesn't look absolutely perfect, but the gasket covers it anyway. The suggestion of getting a new cab is humourous; in Canada we learn to deal with rust.

[dvdswan]

thanks for the replies.  I found a donor cab(ish). the pieces I need are it good looking shape and if I cut them out they are free.  as far as getting a replacement cab... 97% of the truck is original so I'm planning on keeping it like that. I will fix the areas of cancer with replacement pieces and not panels.

I will clean it up this weekend and take some more pics for you guys.

on a side note:  where I found the donor cab the guy has a C60 with a good instrument cluster that I'm trying to get.  it has the tach/gas gauge combo and a vacuum gauge.   hopefully I can convince him.  lol

[RAD77C10]

Sound great! Good luck moving forward!

[dvdswan]

ok, so I picked up the some pieces today.  the lower corners, a spare rally wheel, and tried unsuccessfully to get the cluster.  I'll keep working on that one...

[dvdswan]

so I cleaned up the channel and rust areas.  cut them out and fitted the replacement pieces.

[RAD77C10]

You sure got alot done today! Looks good!

[dvdswan]

so today... well the battery was dead for the camera... so while it was charging I did some grinding, added a little filler, then sprayed some primer on.  got the windshield placed up in the general area.  I thought the windshield gasket was too big.  I then figured it was fine so I tried to install the windshield.   











It all started to fit in all snug and happy and then I gave a little too much English.

[roundhouse]

You gotta use soapy water and a small rope and a good helper to install the glass
And even then you break some so don't feel bad


The patches look good


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[Kren420]

As a career glass guy I can assure you that glass breaks when you least want it.  Just gotta not let it get you down and try again.  Lots of soapy water or a foamy glass cleaner works great for lubricant on that rubber.

[RAD77C10]

Maybe able to get the glass from other truck!