Advice needed on best way to fix windshield rust

[dsimas62]

See my sig for the full thread on Velvet. The bus is OG paint and I'm not touching it, just rolling it like it is, scratches/dents and all. She has character.

However, in the resto, I have new headliner, all rubber, and ragtop assembly to install. I need to fix this worst area of rust before I can move on.

The bus was in a field with no sunroof, slanted downhill apparently, in the Seattle area (RAIN) for decades. I am assuming that water ran down the ragtop rails, into the underside of the roof cap at the front and ran along the fresh air box sides to the top of the interior windshield area. And also out the box vents to the underside of the cap above the windshields on the exterior.

I have a roof cap clip off a standard bus (no skylights) that includes a few inches down the windshield posts and it goes all the way back to the crossbeam (behind the front seats). It has the fresh air box and no rust.

As I said, the bus is completely OG paint, the cap is in fine condition and I don't want to cut it/paint it if possible. And if so, no more than necessary.

Here's a gallery of the pics:

http://photobucket.com/velvetsrust

I am open to suggestions on the best way to go about this?

TIA,
Dawn
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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread:
http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Trans build thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7602210

[Eric&Barb]

Having done a little of that, looks like you will need to cut out all the parts under the roof and "A" and "B" pillars are suspect.
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In Stereo, Where Available!

[Eric&Barb]

This might help.

http://www.thesamba.com/vw/forum/viewtopic.php?t=462164&highlight=wounded+westie
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[joe56vw]

rust is a cancer and the only way to fix it is cut it out and weld new pieces in
there are some amazing pianters around who can blend the paint to look really close to og againwards
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'60 15 window walkthrough
http://www.thesamba.com/vw/forum/viewtopic.php?t=559931&highlight=

why is there no sarcasism button on here?

[dsimas62]

Thanks Eric, great thread. Amazing what is inside there under the cap. As I suspected.

I do want to cut out the rust entirely and use the donor clip in sections. I am just hoping to be able to do all of it *without* replacing any of the roof cap to the drip rail that is in fine condtion with OG paint... Is this possible?

Even if I have to cut the cap off, cut out the windshield areas and reweld clips in, then replace the OG cap and just paint a weld? Can it be separated at the drip rail?
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Dawn

Hugo - '63 ragtop Cal Look bug - Hugo and Dawn - together since 1978
Engine build thread:
http://www.thesamba.com/vw/forum/viewtopic.php?t=482095

Trans build thread:
http://www.thesamba.com/vw/forum/viewtopic.php?p=7602210

[Eric&Barb]

Think you should cut the "A" pillars an inch or so above where the donor piece will come down to. Then you could remove sections one at a time till you are certain you are down to to solid metal.

You might be able to cut off at the overhang just in front of the top of the windshield. Then weld everything into there, but only after thorough rust removal up under the roof and forward of the sun visor panels. That will be a tight place to weld back though...

At worse you will need to grind off the overhang metal off the roof section, and then weld at the rain gutter.

Probably be a good idea to cut the "B" pillars for shoulder seat belts, and with the inner sides of those open you can take a peek to make sure those are not too badly rusted.

Lots of careful prodding around with something like a screwdriver will help show if there is any rust places ready to give out on "B" pillar or other places.
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[50ate]

when i had that bus i remember sitting there looking up at that shit thinking of the best way to tackle that problem area.. its just gonna have to be cut out and welded in.. that white paint will be easy to blend and you wont even be able to tell.. if your not gonna do it your self take it and your donor clip to jason at TRP in sac.. he is amazing and then have it blended...

[dsimas62]