I took the windshield out yesterday and found a bunch of rot in the usual places. I knew I had a leak there but never realized it was this big. The previous owner applied a 1 inch strip of fiberglass cloth and then covered it over with resin. Then placed the windshield over it with the gasket etc. As could be expected the fiberglass lost cohesion and the holes all leaked. In fact the fiberglass strip came right off and was stuck to the windshield gasket.
Although I'd like to strangler the previous owner I'm not really surprised as I expected rot here and I knew I had a leak.
I plan to fill this in with metal, either weld or new steel. I can place a copper backing from behind and build up weld on the outside or ? I'm not really planning on tearing out this big piece and rewelding a patch in. I really suck at welding thin body panels.

So I'm asking advice from the experts and novices here. What would you do?
Thx George

 

Melting lead may work if you clean it really well. The problem is I doubt you can stop whats already rusting.

 

I'm with ya. The guy that had my project car before me used an old street sign and about 1/2" of tar to repair holes in the floor pan.
I think I would replace the rusted metal. Work in sections, maybe thirds, to keep the gap integrity. Cut along above and below the rusted area, remove that portion, and fab a strip of stock to place in to the gap and weld it in. I think that would be a lot easier than trying to fill those gaps with weld, or lead.

 

I would either buy a rust free piece or a repop.

That is a significant job, and probably require a pro.

If you go on YouTube, search under S71 videos. They have a video that shows how to do the repair on a 71 Cutlass.

BTW - this rust out is very common on A body GM cars.

 

Found this video that looks doable. I can get a repop piece for about $70 plus shipping. That might be the plan

 

A "repop" sounds like a lot less welding and WORK. You might be glad you went the "repop" route. Think about zinc plating the new piece if you can get paint to stick.

 

Yep, a repop piece would be great. I didn't know they made them.........

 

Nice Trip. Something I am tackling right now too. Good luck with yours. I appreciate the video. Where did you find the repop ledge?

 

I ordered mine from OPGI but I consider them expensive. A friend pointed me toward them. Sherman also sells it and I'm sure many others. It's easier to look up a 66 Chevelle as the part crosses over to the whole A Body line.
Just a note: OPGI lists two patches. One is listed as 'import' for $68 and the other says nothing but goes for $89. It's my understanding that all these patches are from overseas so maybe it doesn't matter. Either way I got the $89 coming. Maybe I'm getting hosed here, who knows.
If I had had more patience I would have ordered from Sherman but that would have required a phone call the next day so I just ordered from OPGI online that night. Although it's listed as 'in stock' I have no doubt it is getting 'drop shipped' from elsewhere.
I'll post my progress with this as it unfolds for those who are interested. What's sad is as I'm writing this I'm already expecting the worst instead of the best. America has changed.
Getawaycar, if you want to follow along in my madness here's the thread of my build. https://classicoldsmobile.com/forums...tear-down.html

 

I hope this link works for you, It's not too bad of a fix. I used Duraglas after and so far no leaks... wait it hasn't been in the rain. Good luck with it! You've done a great job on your car so far!

http://s296.photobucket.com/user/Tom...?sort=3&page=1

 

Wow, I thought mine was bad! That's some nice work Tom442. Thx for the link