Was up bright and early Sunday to tackle the windshield channel repair. Here is my day with some good results. This is what I uncovered after removing the windshield. Drivers side passenger side not so bad first to cut out the rotted metal. There was a pretty good seciont over the drivers door that was bad as well. Its amazing how big the area gets when you start cutting. Most of the roof edge above this area was good with only minor repairs needed. Let the welding begin. I used the heavy guage metal left over from my full trunk floor as stock. Pretty tedius cutting and grinding patches to fit the wholes. I did the drivers windshield channel in two pieces. Here the first two pieces are tacked in place. You can see the hole in the roof above the drivers door. Here is after replacing the lower portion, grinding the welds and repairing any voids. I wanted to end up with solid steel. The pin holes you see don't go all the way through. On to the roof above the drivers door. Here I tried to keep my patch below the surrounding metal so it could be filled with first duraglass then finished with body filler. I lke to use duraglass for the first coat because it is waterproof when cured. No bubbles if there is a pinhole somewhere. The side path welded and ground smooth. Again the goal was to get a seamless weld. The large divets you see near the pillar is where I touched the origianl lead used to fill that area. They do not go all the way through. It doesn't like the hot weld! The cardboard is there to cath any spatter. A coat of primer \to seal off the metal. It really shows the flaws! Finally the duraglass is worked in to all the pinholes and tosmooth out the rough areas. I will sand this tonight after work and reprime to see whaere I need body filler. The small holes on the passenger side were patched, welded, primed and sealed with duraglass as well.
