Windshield rust repair advice

[stonecat]

Hi, I recently bought a 1978 camper in really good condition with almost no rust, but when I went to replace the original age-frosted windshield I noticed some rust on the windshield lip. I checked out ratwell's pages and what I could find on the forum, and decided to try to fix it myself. I need some advice, though.

There are some small holes where the rust ate through the metal lip, but overall it seems sound. Should I just patch the holes, treat the metal with POR-15, then prime and paint? Or am I just setting myself up for more work in five or ten years? What should I patch the holes with?

Many thanks!!

Here's what the lip looked like when I removed the windshield:

Here's what the lip looks like after my first time using an angle grinder:

Here's a close up of some of the small holes:

[wcfvw69]

There's several ways to attack that. Try and weld the holes closed though some are big. Cutting out those rust spots and welding in new metal would be the best way to fix it long term if the metal is thick enough around the holes. You really need to insure you treat that entire panel to neutralize the rust as well. They also sell complete repair panels for that repair as well though it's a lot more time consuming to install them correctly.

If you go the route of cutting and replacing the metal, you want to make sure when you're done that you treat and seal under the repairs as well. If not, it will start rusting again the repairs.
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[OB Bus]

I had many holes similar in size and location. I wire brushed the area, treated it with phosphor (or equivalent) and then filled/sealed the holes with fiberglass cloth and POR15. It worked.
If I was doing one now there is a POR15 product that is a putty. Might be easier than the fiberglass cloth and less messy.
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Larry in OB
Stop dead photo links! Post your photos to The Samba Gallery!
69 Westfalia and 2002 Eurovan Camper.

[pantone149]

Looks a heck of a lot like mine did a few months ago. I used JB Weld Putty Stick to fill in the holes, then coated with POR-15, painted, and installed windshield.

It's only been a few months so no long term test result is available. I'd think the POR15 will ensure long term goodness.

I leaned too that the JB Weld stuff set fairly quickly the one day I was working in the sun. Moral of the story, work in the shade.

[Bleyseng]

treat the bare metal with Ospho to convert the rust stopping the decay.
How you fill the holes is up to you but use a epoxy primer over the bare metal as I haven't had good luck with Por 15.
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70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!(sold)
76 Porsche 914 2.1L L20c, 120hp Djet (sold)
87 Syncro Westy Titan Red 2.1L 2 knob 100k miles

[markd89]

I'll disagree with all and say you should cut out all of the bottom windshield left to right and weld in a piece from a donor which has no rust.

Mine looked a little worse than yours. We tacked up the holes and POR-15'd it and it didn't last, so we got to do it again..
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78 TDI Sunroof Bus
Los Angeles

[grandpa pete]

If you have a welder ; one option is to make a cap piece where the holes are and weld it over what is there .
The windshield rubber is going to cover it all .
Make shure you clean out the drain holes in the corners or it will rust again .
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63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

[Malokin Martin]

Would anybody braze those holes closed?

[williamM]

That piece from gerson is about $350. It fits like crap- but good thickness and will out last the van-- but need a really good fabricator to fit it.
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opinion untempered by fact is ignorance.

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[VWinVT]

I used panel adhesive on my windshield holes. Was highly recommended on the Vanagon forum. So far so good on my repair.
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1981 Westfalia with a 2001 Cabrio ABA

Small wheel turns by the firing rod,
Big wheel turns by the grace of God.
Every time that wheel turns 'round,
You're bound to cover just a little more ground.

[Busstom]

[Bulli Klinik]

For less than what it would cost to buy and ship a KF section, you could buy a shrinker/stretcher and make your own to replace what's needed. You don't even need a shrinker/stretcher to do it. It could all be done with hammers, it would just take a little longer.

This is one I did some years back.

The key to making this a lasting repair is to not have any filler in the seal zone. Also a good idea to use weld-thru primer at inside of the flange.

Good luck and let us know if you need anymore guidance.[img][/img]
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I've never met a Bus I didn't like.
Mike K
Bulli Klinik
Colorado Springs

[Bleyseng]

Been there....

_________________
70 Ghia Black convert-9/69 build date-stock w/133k 1600 SP-barn find now with a rebuilt tranny and engine
77 Westy 2.0L w/Ljet, Camper Special engine-95hp and with LSD!(sold)
76 Porsche 914 2.1L L20c, 120hp Djet (sold)
87 Syncro Westy Titan Red 2.1L 2 knob 100k miles

[wcfvw69]

That's the way to do it right there Bulli. Nice job.

I could of sworn EIS sold a new windshield repair piece that was around $100 dollars. I didn't see it today..

http://www.busdepot.com/ahs29

I do see Bus Depots selling this. I wonder if it's good?
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

[lil-jinx]

Bulli, did you cut the old piece out or did you over lap it.
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1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy
1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.

[williamM]

[Colonel Mosby]

You know I had this problem too. The right way to fix it is to weld in a new piece of metal. But I tried another way and got good results. I used USC All Metal, POR 15, and some paint and it turned it very good for me. It was a time consuming job but I thought it was worth especially since I do not have any welding skills. Take a look. It might work for you. Good luck!

http://www.thesamba.com/vw/forum/viewtopic.php?p=7769576&highlight=#7769576

[Bulli Klinik]