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orwell84 Samba Member
Joined: May 14, 2007 Posts: 2539 Location: Plattsburgh, New York
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Posted: Fri Mar 23, 2018 6:03 am Post subject: Re: Below Windshield Rust Repair |
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This is my thread on my windshield rust repair using the BD part. There are some downsides to doing it this way compared to using the Gerson panel which come up in the thread.
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0 |
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Wasted youth Samba Member
Joined: July 06, 2012 Posts: 5134 Location: California's Hot and Smoggy Central Valley
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Posted: Thu Mar 22, 2018 11:25 pm Post subject: Re: Below Windshield Rust Repair |
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What has not been addressed in this thread (unless I missed it) is the rust that is occurring on the steel sheet under that Swiss cheese. Not cutting this rotted piece out to get down in there and address the rest of the as-yet unseen rusted metal will only give you or someone else much pain later.
Please do it right. And don't get me started about... patina.
From the Samba Gallery... see that inner skin? Yours is rusting away, too. This guy took the time to get in there and get at it.
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vwwestyman Samba Member
Joined: April 24, 2004 Posts: 5688 Location: Manhattan, Kansas, USA
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Posted: Thu Mar 22, 2018 9:54 pm Post subject: Re: Below Windshield Rust Repair |
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With regards to the rusty relays:
What I've done in the '78 is drill tiny drain holes in what would be the lower corners of the relay covers. I then used some dielectric grease and smeared the grease all over the terminals to help seal them up a little.
Seems to have helped prevent more/further damage. _________________ Dave Cook
President, Wild Westerner Club
1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing |
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tootype2crazy Samba Member
Joined: October 08, 2007 Posts: 1276 Location: St. Louis Missouri
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Posted: Thu Mar 22, 2018 7:56 pm Post subject: Re: Below Windshield Rust Repair |
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The basic tools you'll need to do this are a mig welder (don't get a 220 powered welder for 22 gauge sheet metal, it will blow right through) Best bet is to get that on craigslist. Also you'll need a grinder to grind down your welds and a die grinder with a cutoff wheel to cus precisely. You want a mig welder that uses gas (co/argon) as it can be turned waaay down so you don't blow through thin metal. To weld that thin stuff you need a lot of gas flow and a relatively long wire stick-out, that long stick out lowers the amperage going into the weld and makes it cooler. You will 'stitch weld'-do a dot here, move over there do a dot, you don't want it getting too hot. It's a slow boring process but it's really not hard. Best bet is to get a piece of donor metal from another bus. Try the classifieds or Blair and Sons in Arizona. Having an air compressor so you can use air tools is a major plus. Good luck! _________________ air-cooled or nothing for me
1978 Sunroof Deluxe Bus (daily driver)
1978 Transporter (mom's, making into a camper)
1970 Single Cab 2.1 turbo/EFI 6 Rib, 78 front beam, vanagon backing plates on rear (project)
2001 GTI VR6 (wife's) |
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calo1956 Samba Member
Joined: April 18, 2011 Posts: 703 Location: long Island new york
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Posted: Wed Mar 21, 2018 2:17 pm Post subject: Re: Below Windshield Rust Repair |
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The way i see it you could either drive it the way it is, or run some Gorila tape across it, or bite the bulet, cut it out, weld in the new piece, let it get some surface rust, or just give it some spray patina |
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Yarkle Samba Member
Joined: August 03, 2009 Posts: 1218 Location: the Hills of Western Maine
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Posted: Wed Mar 21, 2018 2:02 pm Post subject: Re: Below Windshield Rust Repair |
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Spike0180 wrote: |
Yarkle wrote: |
Ah..Ok, got it. several vendors are selling the grey EIS one now, so i figured someone here may have bought one. |
I used an EIS grey panel. The metal was thick and pretty hard to work with, but overall fit wasn't too bad. |
if you had to guess (if you you remember) what gauge was it? _________________ Tilda the Mustard Tigress 1973 Squareback (o'''^'''o)
https://www.thesamba.com/vw/forum/viewtopic.php?t=771024&highlight= |
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Poptopcamper Samba Member
Joined: June 23, 2012 Posts: 490 Location: Sheridan, Wyoming
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Posted: Wed Mar 21, 2018 7:32 am Post subject: Re: Below Windshield Rust Repair |
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If you just want to seal things up until you can do a proper weld job, plumbers use a bright shiney silver tape that's sticky like duct tape but water proof. You can get a roll at Home Depot in the plumbing Dept. It will look like you put a wide strip of chrome under your windshield. Funky, but it will keep out the water. If it's going to be a while before you do the job you might want to encapsulate the exterior rust with POR15 which you can order on line. A starter kit should be enough. But remember that it's still rusting underneath. Have fun!😎 _________________ If you only have one tool in your tool box, and it's a hammer, pretty soon, everything looks like it needs to be whacked!
1978 VW Riviera
2021 Dodge Ram 3/4 ton
2020 VW Tiguan
2001 Harley Electraglide Classic
1986 BMW R 800cc motorcycle
2002 Chevy Camaro Z28
1999 Harley Sportster 1200 Custom |
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Spike0180 Samba Member
Joined: June 06, 2015 Posts: 2269 Location: Detroit, Michigan
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Posted: Wed Mar 21, 2018 6:33 am Post subject: Re: Below Windshield Rust Repair |
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Yarkle wrote: |
Ah..Ok, got it. several vendors are selling the grey EIS one now, so i figured someone here may have bought one. |
I used an EIS grey panel. The metal was thick and pretty hard to work with, but overall fit wasn't too bad. _________________ Brutis Patches Izabich: 1970 VW Transporter - 1776cc DP
Current State: Projects never truly end...
Location: Grosse Pointe, Michigan
Other cars: 2003 F150, 2003 Jetta GLI vr6-6sp
Sambastic: adj; the quality of being nit picky, elitist, expecting everyone to do things the way they believe is best with no regard to situation, "sambastic" |
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Alan Brase Samba Member
Joined: March 28, 2004 Posts: 4532 Location: Cedar Falls, Iowa
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Posted: Wed Mar 21, 2018 12:25 am Post subject: Re: Below Windshield Rust Repair |
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1967250s wrote: |
Myself, I am pretty sure the body dies VW used changed from the early to late bays,especially the nose and windshield area, along with the shape of the windshields, particularly the corners. How that affects the new metal available is a guess. I have always thought the early bays, '68 &' 69 had a more rounded nose than later ones. I maybe wrong, but somehow the nose appear more rounded. I'd be very surprised to hear that the same stamping dies were used for 11 years. Has anyone else noticed this? |
You are wrong. The skins are interchangeable, but for the turn signal cutout locations.
Windshields are the same part as well.
Maybe the colors make it seem different?
Al _________________ Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home |
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1967250s Samba Member
Joined: May 02, 2007 Posts: 2137
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Posted: Tue Mar 20, 2018 10:41 pm Post subject: Re: Below Windshield Rust Repair |
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Myself, I am pretty sure the body dies VW used changed from the early to late bays,especially the nose and windshield area, along with the shape of the windshields, particularly the corners. How that affects the new metal available is a guess. I have always thought the early bays, '68 &' 69 had a more rounded nose than later ones. I maybe wrong, but somehow the nose appear more rounded. I'd be very surprised to hear that the same stamping dies were used for 11 years. Has anyone else noticed this? _________________ '72 Elm Green Deluxe |
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orwell84 Samba Member
Joined: May 14, 2007 Posts: 2539 Location: Plattsburgh, New York
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Posted: Fri Mar 16, 2018 4:58 pm Post subject: Re: Below Windshield Rust Repair |
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The green panel is meant to be welded in along the bulge section, above the belt line. I think the green panel has had good reviews, but sometimes stamping dies can become less precise with wear. I don't know if that has been an issue or not. I used the BD strips. It was a pain in the ass. I would say your panel is way too rusty for this. I think people have used the EIS panel. It's a sucky job either way, even with a perfect replacement panel. |
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Yarkle Samba Member
Joined: August 03, 2009 Posts: 1218 Location: the Hills of Western Maine
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Posted: Fri Mar 16, 2018 12:15 pm Post subject: Re: Below Windshield Rust Repair |
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williamM wrote: |
[img]
The green panels need a LOT of custom fitting. The corners were the worst. [/img] |
WHEN i get to it, ive got to tackle this job. Is where youd cut it if you had to do it again? It looks like you just cut out below the belt line and completely replaced it? _________________ Tilda the Mustard Tigress 1973 Squareback (o'''^'''o)
https://www.thesamba.com/vw/forum/viewtopic.php?t=771024&highlight= |
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lil-jinx Samba Member
Joined: August 14, 2013 Posts: 1109 Location: New Brunswick,Canada
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Alan Brase Samba Member
Joined: March 28, 2004 Posts: 4532 Location: Cedar Falls, Iowa
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Posted: Sun Mar 11, 2018 8:51 am Post subject: Re: Below Windshield Rust Repair |
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Yarkle wrote: |
was the busdepot one the little metal strip one or the one similar to the EIs one i linked (kinda looks like the klassicfab, but grey?) |
The little one. I think it is Just Kampers label.
Al _________________ Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home |
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Yarkle Samba Member
Joined: August 03, 2009 Posts: 1218 Location: the Hills of Western Maine
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Posted: Sun Mar 11, 2018 5:59 am Post subject: Re: Below Windshield Rust Repair |
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was the busdepot one the little metal strip one or the one similar to the EIs one i linked (kinda looks like the klassicfab, but grey?) _________________ Tilda the Mustard Tigress 1973 Squareback (o'''^'''o)
https://www.thesamba.com/vw/forum/viewtopic.php?t=771024&highlight= |
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Alan Brase Samba Member
Joined: March 28, 2004 Posts: 4532 Location: Cedar Falls, Iowa
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Posted: Sat Mar 10, 2018 10:35 pm Post subject: Re: Below Windshield Rust Repair |
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Miklo wrote: |
I’ve been wondering the same question...
My project 70 lower windshield looks very similar. Rusted/rotted out.
I’ll mention as well, windshield leaks run all over the fusebox killing the relays... ask me how I know.
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Generally, if you bought KF panels directly and had trouble fitting them, he would take some action, make it better just to improve the product.
I recently bought the UK made part from Bus Depot, and it is so bad one almost wonders if it was for a different window! But this vehicle is not too badly rusted, so, I'm just gonna make this into patches. Plus, I bought a shrinker/ stretcher, gotta set it up and learn!
Auto Craft may be better yet. Never tried them. I was so pleased when Gerson came on to the scene, I'll tolerate a little, I guess!
Al _________________ Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home |
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Stevenb83 Samba Member
Joined: March 07, 2018 Posts: 4 Location: Moore,OK
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Posted: Sat Mar 10, 2018 3:40 pm Post subject: Re: Below Windshield Rust Repair |
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Dang! Mine doesn’t have any of the fuse block or relays, I’ve got to buy new, probably got pulled out because they were like yours |
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Miklo ¡Chale!
Joined: August 27, 2008 Posts: 2058 Location: Antelope Valley, Ca
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Posted: Sat Mar 10, 2018 3:30 pm Post subject: Re: Below Windshield Rust Repair |
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I’ve been wondering the same question...
My project 70 lower windshield looks very similar. Rusted/rotted out.
I’ll mention as well, windshield leaks run all over the fusebox killing the relays... ask me how I know.
What I found... Check out the relays in the bottom picture.
_________________ ✠Miklo✠
'55 Type1 "Ozma"
'66 Type1 "Charlotte" RIP
Antelope Valley's Mobile Air-Cooled Guru
Dr OnHolliday wrote: |
As I remember it, lowriding was not one of the criteria that Adolf gave to Dr. Porsche... |
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Yarkle Samba Member
Joined: August 03, 2009 Posts: 1218 Location: the Hills of Western Maine
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Posted: Sat Mar 10, 2018 2:12 pm Post subject: Re: Below Windshield Rust Repair |
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Glenn wrote: |
Yarkle wrote: |
dotn get pictograms very well: |
Then what is this in your signature?
[o____o] |
Its my bus!
Pictograms i doodle make perfect sense to me, its just ones from other people that i have trouble deciphering.
I wonder why there are so many mixed reviews on the green panels, could it be that buses over the years have just deformed a bit? Im leery of EIS in general, especially when the price is well over a hundred bucks cheaper. _________________ Tilda the Mustard Tigress 1973 Squareback (o'''^'''o)
https://www.thesamba.com/vw/forum/viewtopic.php?t=771024&highlight= |
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dirtkeeper Samba Member
Joined: February 19, 2008 Posts: 3200 Location: Left of everywhere
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Posted: Sat Mar 10, 2018 11:25 am Post subject: Re: Below Windshield Rust Repair |
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as mentioned you have some substantial rot there. That said i have made temporary repairs (last a few years) in those areas of a bug, i used high quality metal tape as used in the heating and air conditioning business. sticks well, thin, can be built up stronger with a few layers, can be painted and massaged flat and smooth. I had a picture of this but cant find it now. Must clean the surface very well first. can even be slipped under the rubber, I have made permanent repairs to smaller rotted areas using fiberglass bondo. Has lots of fibers in it to grab and stick around the damage dries hard and sandable. For a permanent fix you would need to make sure all rust is removed, or treated and sealed, difficult unless you can get in and observe the inner side of the panel.. |
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