Ok... how would you attack this?? pinch weld windowframe rust

B

BoostedOne

So I have this windshield frame for a rubber window seal. Like a lot of these the part that makes up the lip for the seal is also the joint between the inside and outside panels.

Mine has rust at a bunch of the welds, sometimes with holes in the lower panel and a few spots with rust holes in the upper panel...





Ive thought of using the shrinker and stretcher to try to remake two replacement pieces. .. also considered cutting the lip out, patching the holes, then replace the lip with a single peice of metal and a fillet weld but that seems kind of hokey...
 
Looks like you have more rust problems underneath it. I would drill out the spot welds, remove the cowl and fix the underlying rust, make some patches for the cowl and weld in. Prep and epoxy everything then reassemble.
 
Ya know SOF.... When I read that I was thinking "this guy is really was living up to his name" haha.. Part of the reason it just seemed like a ton of work.. other reason was this is one of those spots that always rusts on these cars... I have parted or built out a bunch of these lately.. they always have rust. This was the first one I have 2aved though I couldn't just touch the holes with the welder after blasting and be fine...
But I do have this front clip on my back property line off a Real rust bucket. It was horrible. Could have knocked me over with a feather when I saw how solid it was. Grabbed the sawzall and chopped it out before dark. Just trying to decide if I should go thru the hassle of dealing with the spot welds and butt joints on the ends as well as fixing the rust on the car side, or just cut the lip and 1/2" of material to each side and weld it in like a 30 inch by 1 inch patch.. im leaning in that direction.

But had I not come across this panel the more your suggestion sunk it it did make the most sense.

 
And when you pull in that windshield make sure to use some sealer so water doesn't hang in there and rot the replacement out.
 
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