A little surprise after removing the windshield (1 Viewer)

[canman]

I brought my truck to the glass shop last week to have the windshield replaced after a stone chip resulted in a crack right across my line of sight. An hour later they called and said I should come and have a look. This is what they found.

Fortunately, a friend has a JDM donor vehicle he is parting out. I'll be using my plasma cutter to cut out the good metal from the donor vehicle. I never noticed any signs of water around the tunnel. They also mentioned that the windshield had been completely caulked in the gasket. This was not the case when they removed the windshield from donor vehicle.

 

[Huis Clos]

Wow, that is some nasty cancer, I hope all works out well for you.

 

[thatcabledude]

As far as I know the windshield is supposed to have the sealent in the gasket too. Was the glass removed from the donor truck factory? You might want to double check the installation instructions in the FSM.

 

[alltel05]

Ugggg

 

[chapel gate]

I hate rust more than anything.

I have replaced both the front and rear windscreens myself. not a job I enjoyed.

iirc post 95 are glued into the gasket. a adhesive and a sealant are used I think this has something to do with the airbag.

 

[scrowley]

Mine had a little rust too. The windshield that was in there was aftermarket with an aftermarket gasket. ( = leaks) Now I have an owm gasket installed per FSM and its all good.

 

[firetruck41]

Polyurethane adhesive is supposed to be used on both mating surfaces of the seal, IIRC. Check the "how-to" in my signature below, in that post, there is a link to the FSM window installation pages.

 

[canman]

Cut the metal out of the JDM donor vehicle last night, but to do so we had to remove the dash. I'll have to do the same on mine. I've searched mud and didn't find anything for latest style dash. Any ideas?

 

[canman]

Now that I finally have the dash out, I have a better idea of what I'm dealing with. This is going to be a bit$& to repair properly.

 

[canman]

We'll after some delays in getting my surgery and some time to recover, I can see the end is almost in sight. Hoping to have it all welded up today with some primer.

 

[NLXTACY]

Nice work. First time I've seen this type of repair on an 80.

 

[canman]

Thanks. Last pc welded in and now in primer. What a pain in the a$$ this has been. Now I'll somehow have to get some primer/ paint on the bottom sides of the welds.

 

[scrowley]

Nice work on the unexpected repair.

 

[canman]

Thanks. Trying to do my best, but by no means am I a body man. I have a lot of respect for those that can weld, paint, etc. and turn rust buckets into collector items. BTW - Very nice work on the remodelling.

 

[SupraTuRD]

Looks like a good fix... your method is much better than trying to cover it up.