How to address rust hole behind windshield trim? (3 Viewers)

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LazarusTaxa

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Jun 28, 2020
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Location
Bend, OR
I recently picked up a 100 and unfortunately, though the rest of it is quite clean, mine suffers from a terribly done windshield install... pulling the trim reveals the common rust around the side and top edges... Though, only one area is rusted through (Pic below), I've cut away enough of the urethane and seals in the other areas to be 99% sure it's not rust ed through anywhere else. Further, the installer decided to use self-tappers instead of the factory rivets, so I've got additional holes in the A-pillars.

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I am well aware that the proper repair is to have these holes welded and all of it repainted. The issue with that is that the welding is gonna heat these areas up enough so that a much larger area is going to need repainting... The entire A-pillar and the roof all the way back to the sunroof. I've gotten quotes from the only two places in town that will do work like this, and both quoted 2500-5000 for pulling the windshield, fixing the rust properly, repainting, and reinstalling the windshield.

I do not want to spend 3K on this right now.. like at all...

What if.. I pulled the windshield, wirewheeled all the way down to good clean metal, and then used epoxy putty or Permatex liquid metal to fill these holes? I'd then paint with a 2K epoxy primer, 2k single-stage top coat, and have the windshield reinstalled. Would this be an adequate repair? Would there be any serious issues with this?

Any insight is appreciated.
 

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