Windshield Woes (Leak)

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jaymar

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So, windshield Leaks at top when raining. More or less under this spot here. For those of you who have seen this kind of thing before, what can I expect to find underneath this – – and what am I going to need to repair it? I’d like to have the proper items on hand before digging in… Thanks!

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For the correct glue to use on the rubber windshield gasket go to post 18 listed in the thread below. As for that bubble rust you'll need to remove all that rust, then repair any underlying metal damage before you prime it and repaint your base color.
 
For the correct glue to use on the rubber windshield gasket go to post 18 listed in the thread below. As for that bubble rust you'll need to remove all that rust, then repair any underlying metal damage before you prime it and repaint your base color.
You’re thinking there may not actually be a hole in the metal ( he asked hopefully )?
 
You’re thinking there may not actually be a hole in the metal ( he asked hopefully )?
I'm sorry to tell you this, you won't know the answer to that question until you've remove all that bubbled paint to see what's hiding underneath.
 
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I had a similar problem but not as far back on the roof. It went across the entire length of the windshield. I had the windshield guy remove the windshield, I used my grinder to get rid of the rust, then I coated with POR-15. Fortunately it did not hole through. I then took it back to the windshield guy and had them heavily seal it. You really won’t know how bad it is till you pull the windshield.
 
I had a similar problem but not as far back on the roof. It went across the entire length of the windshield. I had the windshield guy remove the windshield, I used my grinder to get rid of the rust, then I coated with POR-15. Fortunately it did not hole through. I then took it back to the windshield guy and had them heavily seal it. You really won’t know how bad it is till you pull the windshield.
Define “heavily seal it.” New gasket, more?
 
Define “heavily seal it.” New gasket, more?
reused the gasket as it was only a couple years old and in good condition, but applied a liberal amount of sealant, gasket to glass and gasket to body per fsm instructions, this step is critical.
 
You will have significant rust under that gasket if not a hole
and likely more rust hidden under the gasket.

Personally, I would take the vehicle to a body shop to have the rust repaired.
The body shop can have the glass guy remove the windshield, then come
back to install the new glass after the repairs are made.
 
I assume that IF there’s metal loss, a patch can be welded—even if it’s a sealing suface? There seem to be nascent versions of this bubble rust along the roof-side gasket edge.
 
There is for sure a hole there. You could patch in with fresh steel, which would be ideal, but if you don't want to dink around with that, get as much of the rust out, treat what is left with acid and then POR15 it and then do your best Bondo job.

I had a tree fall on my little truck a few years ago and it smashed the windshield out and caved in the roof. I got it back up with a bottle jack and a 2x4 (think home job Porta Power like they use at a body shop) hammered the seal area back to close enough and then tossed in a new windshield. It did fail because I didn't do a good job of roughing up the surface of the POR15 before I primed and painted that area and the paint peeled back from the POR15 which made the 3M glue I used pull with it. I got the opening roughed up better and then I hired a local glass company to re-install the windshield. It's been fine for 2+ years since then.
 
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