Hi,

Got rust holes each side of the windshield as seen from pictures. These were repaired sometime in the past with filler but as usual didn't hold and the bubbles appeared again. I would like to spot weld a piece inside these if I could but am worried that the windshield will crack with the heat. Don't want to try and remove the windshield as if it gets broken I can't get a replacement in Ireland. Could I rivet in an aluminum piece or would that be stupid? don't know much about this type of stuff.

Could any of you guys with welding experience let me know what you think. What is the best way to repair this. If I try remove windshield is there a big chance it will break and as said above have no access to replacement.

Thanks.

 

Duct tape, fire retardant blanket, etc. (or Irish facsimile) the windshield to protect it from sparks, then cut out and weld in the replacement piece. There might be a danger of heating up and melting the windshield sealant, so be prepared for that. Slow and steady cutting out and welding. Ideally the windshield should be removed.

 

I think the biggest concern is stopping the rust that is there from coming back. If you don't do that, welding a piece in is just going to rust. Maybe even faster than this. If water got in there, you need to use a heatgun or something to get the moisture out. Ideally you need to get some kind of rust inhibitor all up in there. Try and clean up ANY rust that is inside as well, before doing that. Then get the rust inhibitor in there as far as you possibly can. Then repair, either weld(risky with windshield in) or use fiber cloth repair. The prep is going to determine how long it lasts before rusting again.

 

Also remember that the A pillar is filled with sound deadner/foam.
Its gonna hold moisture no matter what so you can expect it to
rust again.

 

When doing the welding just do a bit more than a spot then let it cool off. Then do another. This will keep heat soak to the windshield to a minimum. It will take time though as you do not want to use water to cool it.

 

I have pulled out as much of the foam or sound deadner as I could. I have removed as much rust as I could from inside the A pillar. I can get up into the A pillar from inside the car with a hose so I can pump in some rust inhibitor. I will try the welding and hopefully won't do damage.

By the way how hard is it to remove the windshield. High risk of breakage?

Thanks.

 

It depends on the sealant condition. If its original or correct, than a glass pro should be able to remove it, if it's been redone w improper sealant or something, could be a problem. Might want to get a glass guy to look at it.
Especially if you can't remove the windshield, I would consider using POR15 paint and fiberglass or metal mesh. It's going to be a difficult weld for the inexperienced because you won't be able to support it from behind. I have rebuilt whole floors with por15 and fiberglass. Very strong and never rusts again.
Did the pillars fill with water? I haven't dealt with a pillar rot before. Are the rest of he pillars solid? I would def be concerned about reoccurring rust so some sort of rust inhibitor will be necessary.

 

Yes might be better to get the advice of a Glass installer. Think there are some mobile services around.

I don't know how water got into the pillars. I think it is unusual for rot to occur here. I would like to get all that sponge out of the pillars but that's not possible. I have removed it all around the rust spots so hopefully that will be enough.

Thanks.