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How would YOU fix this rust?
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///Mink
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PostPosted: Sat Nov 24, 2007 3:36 pm    Post subject: How would YOU fix this rust? Reply with quote

OK, I'm back to work on my '74 coupe. I'm nearly done with the bodywork, and plan to spray it in the next month or so. The last bit of bodywork I need to do is to fix the rot in the lower corners of the front windshield frame.

Ideally, I'd section in pieces from a donor car, but I don't have one. So I thought of a couple of options:

1. Cut separate pieces for the channel and the cowl and weld them together where they meet. In other words, the bend between the cowl and channel would actually be a welded seam.

2. Bend a hunk of metal in a brake and then make a series of relief cuts in it so I can bend it to match the curvature of the frame.

3. Some other idea I'm not thinking of (this is where you come in).

Currently, I'm leaning toward #2, but if you've done this before, please chime in...

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blarneyman
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PostPosted: Sat Nov 24, 2007 5:52 pm    Post subject: Reply with quote

I would go with #2. I did the same thing on my 70 but in a different area. worked out pretty good, just time consuming.
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70 140
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PostPosted: Sat Nov 24, 2007 5:58 pm    Post subject: Reply with quote

Is it to thin to build up and close with a welder? It looks pretty thin.

I vote for option two. The more relief cuts you make the less the gaps will be between cuts = easy to close up with some welds.

I would also coat the area under the seal with POR silver (metal strengthener) I have had great luck with this stuff.
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westcoast-paul
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PostPosted: Sat Nov 24, 2007 6:11 pm    Post subject: Reply with quote

why not find a section from a donor car on the net?

ICY has a crap load of extra ghias.
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wcfvw69
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PostPosted: Sat Nov 24, 2007 6:16 pm    Post subject: Reply with quote

I will drill out the spot welds along the rusted part and cut out the entire rusted piece. If you can't buy it aftermarket you can certainly buy that piece from a donor.
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rumplestilskin
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PostPosted: Sun Nov 25, 2007 8:29 am    Post subject: Reply with quote

umm i don't think that last poster noticed that is a pic of a windshield frame. and this is a ghia (1 giant hunk of steel).

lay a piece of card stock over the piece u will be cutting and cut and trim and bend until u get it how u want, than fab the piece . when your fabbing is perfect than cut the body
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wcfvw69
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PostPosted: Sun Nov 25, 2007 8:48 am    Post subject: Reply with quote

rumplestilskin wrote:
umm i don't think that last poster noticed that is a pic of a windshield frame. and this is a ghia (1 giant hunk of steel).

lay a piece of card stock over the piece u will be cutting and cut and trim and bend until u get it how u want, than fab the piece . when your fabbing is perfect than cut the body


Actually I did. That top piece (that's rusted) is spot welded (or sandwiched) to the bottom of the windshield piece. You should drill out the spot welds then use a pattern like you discribed.
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OTO X58
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PostPosted: Sun Nov 25, 2007 9:23 am    Post subject: Reply with quote

wcfvw69 wrote:
rumplestilskin wrote:
umm i don't think that last poster noticed that is a pic of a windshield frame. and this is a ghia (1 giant hunk of steel).

lay a piece of card stock over the piece u will be cutting and cut and trim and bend until u get it how u want, than fab the piece . when your fabbing is perfect than cut the body


Actually I did. That top piece (that's rusted) is spot welded (or sandwiched) to the bottom of the windshield piece. You should drill out the spot welds then use a pattern like you discribed.


HAHA, did you really think that someone pounded out the Ghia body out of one sheet of metal? If I were you I would cut a piece out of a donor car.
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rumplestilskin
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PostPosted: Sun Nov 25, 2007 10:54 am    Post subject: Reply with quote

repairs like this. i wish we could use photoshop in real life.
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///Mink
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PostPosted: Sun Nov 25, 2007 12:35 pm    Post subject: Reply with quote

OK, it's official...I'm a dimwit. After posting this thread, scrounging the classifieds, and asking a few friends, I looked up and realized I had this hanging on my garage wall...

(and it appears that there's enough metal left on it for the sections I need.) Woohoo!

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I'll post a few pics of the repairs.
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70 140
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PostPosted: Sun Nov 25, 2007 12:38 pm    Post subject: Reply with quote

So you aren't going to use kitty hair? Wink
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rumplestilskin
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PostPosted: Sun Nov 25, 2007 4:02 pm    Post subject: Reply with quote

what a dork.



just do what i do. say u were drunk at the time.... it works every time!
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///Mink
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PostPosted: Sun Nov 25, 2007 6:43 pm    Post subject: Reply with quote

Well, having the right parts certainly made this job a whole lot easier!!

First, I positioned the piece I cut from the donor using the wiper pivot as a reference point - this ensured that I matched the curvature correctly.

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Then I marked and cut the donor piece off so that all the rust was covered.

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Then I cut out the rotten area on the lines and cleaned it up:

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Quick test fit of the donor bit:

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Donor bit tacked in:

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Welded in and cleaned up:

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wcfvw69
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PostPosted: Sun Nov 25, 2007 6:51 pm    Post subject: Reply with quote

Damn! Nice work!
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70 140
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PostPosted: Sun Nov 25, 2007 8:05 pm    Post subject: Reply with quote

It looks like the car has been a few colors in its life.
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///Mink
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PostPosted: Sun Nov 25, 2007 8:09 pm    Post subject: Reply with quote

70 140 wrote:
It looks like the car has been a few colors in its life.


Tell me about it. It makes feathering the edges of the paint a total bitch. Brick wall By my count, there are about 4 colors on top of the original.
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OTO X58
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PostPosted: Sun Nov 25, 2007 10:01 pm    Post subject: Reply with quote

Nice job!!
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Gary
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PostPosted: Mon Nov 26, 2007 6:49 am    Post subject: Reply with quote

Nice work, Tom. Looking good and I'm glad you didn't scrap the fattie!
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grelland
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PostPosted: Mon Nov 26, 2007 4:15 pm    Post subject: Reply with quote

Nice work.

Just a tip, though, the welds get a lot nicer if you grind away the paint before you weld. Actually the welding itself becomes much easier.
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