Lower windshield frame rust (1 Viewer)

[CalnSam]

Hey guys, I got the unfortunate call from the glass shop saying my lower windshield frame was nonexistent. I went to check it out and it was worse than I expected. It’s a shame because the rest of the body and frame aren’t very rusty. I am confident in being able to weld new metal in, but the shape and contour leave me wondering if this portion of body metal is available individually, or if any members/vendors have a donor they would cut out for me. I see this lower portion is spot welded onto the top edge of the firewall. There is some remnants of the flange left on the passenger side, but the driver side is totally gone!

Thanks for any help you can provide.

 

[Hornd]

Here is what I did but Appears you are Beyond this Point

 

[CharlieS]

Have a good body shop make a repair panel. Not Maaco, someone old school who knows how to use a shrinker/stretcher, english wheel, bag and hammers. They can make a repair panel and tig it in.

 

[Nad Aitch]

On the bright side that piece shouldn't be too hard to find unscathed on a wrecked truck, you know how to weld, and perfect paint match isn't vital in that area. Custom panel seems like the most expensive path to me.

 

[bicycleagent003]

I had rust under my windshield recently when I had it replaced, too. Mine was not nearly as bad as yours. I had a guy come out who specializes in metal fab and custom work. He said making a replacement piece in that area, especially of the size you are looking at, is going to be tough to make work right. Also, if you're welding in that area, you'll be pretty close to the back of the dash, which is rubber and foam. I think if it were me, I'd get that entire bottom of the windshield frame from a wrecked truck and have it welded in. I think you might have to remove the dash to get that in there, and you're right above the firewall. Honestly, it might turn into a major repair. I'm sorry, I hope it's not as involved as all that. Of course this all depends on your time, budget and commitment to this particular 80. Good luck with the repair, please keep posting as to how to work it out.

 

[RinconCruiser]

I had rust under my windshield recently when I had it replaced, too. Mine was not nearly as bad as yours. I had a guy come out who specializes in metal fab and custom work. He said making a replacement piece in that area, especially of the size you are looking at, is going to be tough to make work right. Also, if you're welding in that area, you'll be pretty close to the back of the dash, which is rubber and foam. I think if it were me, I'd get that entire bottom of the windshield frame from a wrecked truck and have it welded in. I think you might have to remove the dash to get that in there, and you're right above the firewall. Honestly, it might turn into a major repair. I'm sorry, I hope it's not as involved as all that. Of course this all depends on your time, budget and commitment to this particular 80. Good luck with the repair, please keep posting as to how to work it out.

I have this section on a parts car but you can make a template of thin cardboard and make the piece from 20 gauge cold rolled steel. It’s a flat piece. Get a hold of me if you want more information. I’m in the middle of replacing a windshield now on one of my FJ80s.Daniel

 

[RinconCruiser]

I have this section on a parts car but you can make a template of thin cardboard and make the piece from 20 gauge cold rolled steel. It’s a flat piece. Get a hold of me if you want more information. I’m in the middle of replacing a windshield now on one of my FJ80s.Daniel

 

[CharlieS]

If you can weld, this is no big deal. The stuff about burning the dash is poppycock, if you weld much, you know how to avoid that.

 

[bicycleagent003]

If you can weld, this is no big deal. The stuff about burning the dash is poppycock, if you weld much, you know how to avoid that.

Good to know. I don't the first thing about welding. Thanks for that.

 

[CalnSam]

Wow! Thanks for all the responses guys, sorry i never updated this sooner than 6 months later. when i posted this originally, i was going through a tough time, my 28 yo brother had just passed away a few weeks prior, we all got wicked covid 19 for the first time at a family gathering to celebrate his life...then this rusted windshield frame on my wifes newly acquired dream rig... uhg to say the least!

it was an unusual winter in Minnesota, with no snow on the ground in February, i drove the windshieldless lx home from the glass shop where it had spent the night, (if you have never driven a vehicle without a windshield in your life, you have to try it, exhilarating!) my shop with a welder and tools was 20 minutes away from my house, it was only 20 degrees outside and i couldn't afford to catch a cold again...so it was then towed (backwards) to my shop. AAA!

i didn't receive any responses for donor patch panels here, i did get a nice response from classic cruisers in salida as always, but they said they had recently cut the same patch panel out of fj60 and it was a pain, so they needed 600 bucks to cover their time (understandable but out of my budget, but maybe not yours?) i knew i had to make it work for myself... i had been gifted a donor windshield wiper cowl cover from a mud member years before, lue yang if youre still out here, thanks a ton...

with the concave as well as bowed shape of the missing metal, and not very many landmarks left to create the shape from...i carefully dissected the donor wiper cowl, and got the 1" tall strip of metal i needed cut off, and tack welded it carefully in place... 200 tack welds later, a fair bit of grinding, primer and paint, and we called the glass guy over to finish the job!! the new glass went it great, looks great, and has been enjoyed with extra appreciation ever since! 1 tiny weld burn on the dash, thankfully unnoticeable from almost all angles

 

[Marvelicious]

I guess the real test is whether it all seals well over the long haul, but it looks good to me! Nice job.

 

[CalnSam]

I guess the real test is whether it all seals well over the long haul, but it looks good to me! Nice job.

the windshield gasket is doing alot of work in that particular area, grasping both the flange i welded in, the glass above it, as well as swooping over the wiper cowl, all in the same square inch... considering how bad it was rusted before i knew about it, no signs of water intrusion below, prior or present, i am moving forward in life hoping for the best with fingers crossed! now my personal lx450 in black, parked next to this one daily, which i know is more rusty in general all over comparatively.... got a wicked rock chip on the highway a few months ago... you can imagine where my mind has gone LOL. we will cross that bridge when we come to it...

 

[CharlieS]

Sounds like a rough patch. Hope everyone is recovering. Condolences.

Nice work fixing it.

Fiberglass blankets are great for protecting materials from weld splatter, if you find yourself doing something similar again. Cardboard works too, but has unfortunate side effect of burning. hahaha

 

[BILT4ME]

the windshield gasket is doing alot of work in that particular area, grasping both the flange i welded in, the glass above it, as well as swooping over the wiper cowl, all in the same square inch... considering how bad it was rusted before i knew about it, no signs of water intrusion below, prior or present, i am moving forward in life hoping for the best with fingers crossed! now my personal lx450 in black, parked next to this one daily, which i know is more rusty in general all over comparatively.... got a wicked rock chip on the highway a few months ago... you can imagine where my mind has gone LOL. we will cross that bridge when we come to it...

Seeing threads like this gives me the shivers, as I know I have rust around my windshield from a poor replacement years ago. I need to get it replaced because it's got a huge crack and now I'm getting leaks while driving. It's also my DD so I'm going to have to figure out a way to do what you've done as well as get the glass installed.

Nice work and thanks for the pics. It helps me understand how I need to approach this.