Rust around windshield, what is the best option to repair?

kinmont · Feb 7, 2021

I recently bought a '86 Sierra and I'm stoked.... :cheers:

I don't have much experience so I am hoping to get some help on repairing the on rust.

This is the first truck project for me, any advice is much appreciated!

Bottom corner windshield on both sides fully rusted through, also rust and a decent hole in the fire wall

Anyone have any experience repairing or replacing these areas?

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Snoots · Feb 7, 2021

Without knowing what tools you have at your disposal, that's a tough one.

I'd start by buying a steel bristle brush and a can of spray rust converter and sealer.
That should slow it down until you get ALL of your ducks in a row.

bucket · Feb 7, 2021

That hole on the upper cowl area is kind of an odd one. It might have stemmed from someone's monkey business in the past.

The easiest thing to do is get some good metal from a donor cab and splice it in. You can cut out the bad stuff and make your own replacement panels, but if it's something you've not done before, it may be frustrating and take multiple tries. Either way, a little fabrication and some welding are going to be needed.

kinmont · Feb 7, 2021

Thanks for your replies.. a donor cab is the next mission for me. I don't have any welding experience but Im going to get this done, a great opportunity to learn (with help of course).

Had to pull some caulking to really see what was up so that may have made the issue worse in our rainy climate.

shiftpro · Feb 7, 2021

When I'm collecting parts, such as cabs, that rust spot would be a deal breaker for me. A completely rusted out floor, rockers, corners and cab supports underneath are easier to repair than this mess.

As the bucket said, best to find another cab and either switch cabs completely or cut out the frame and graft onto your cab. One good thing is, you will
become a fine body man by the end of this journey.
And welcome to the site!

Rusty Nail · Feb 7, 2021

shiftpro said:
When I'm collecting parts, such as cabs

Lmao.

shiftpro · Feb 7, 2021

Rusty Nail said:
Lmao.

It makes me happy, give me a break!
I have four of them in my yard and a few I need to haul home this summer.
Guys are figuring out I'm the square body man out here and slowly but surely I'm selling parts... it's fun.
I don't a woman in my life demanding attention so other than our really bad government, I'm kinda free to do as I please!

kinmont · Feb 7, 2021

Thanks - yeah that seems like the right call - just have to find one... the good news is there really isn't anything else major... frame is good just some other minor surface rust... you gotta start somewhere!

any thoughts on apporx cost to pick up a donor cab? just so I have a ballpark number

curse · Feb 7, 2021

Free if you come to Michigan and pick it up!

Snoots · Feb 7, 2021

ROAD TRIP!!!

kinmont · Feb 7, 2021

on my way...

peats · Feb 8, 2021

that's a tough fix even for someone with welding and fabrication experience. i'd look for a cab.

Grit dog · Feb 8, 2021

peats said:
that's a tough fix even for someone with welding and fabrication experience. i'd look for a cab.

I’ll find out soon!
Normally something like this would be a deal breaker for me too, but I was able to overlook it on our truck because the rest was so clean. Figured one b!tch of a challenge would be ok and make for a good story later....hopefully, lol.
This is the worst spot on mine. Couple other spots have pin holes but the cowl and firewall are cherry. I attribute it to the visor that was on it likely.

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Grit dog · Feb 8, 2021

For that area I got an old cab pillar and removed the skin off of it and will cut and patch new skin in.
Might do one more area, the rest are getting rust reformer sprayed inside, ground down and mudded up.

OP, the good news is you don’t really have to weld, just tack. Like 100s of tacks. The bad news if replacing it the right way is drilling out all the spot welds and trying not to make more of a mess of the cab or donor pieces.
It took me close to 2 hours to get the donor piece of skin off the junk A pillar. And I’m now not going to attempt to remove the welds from the inside of cab. Think I can patch it in a little differently. Will see....

Advice. Get a spot weld drill. I didn’t have one. But a buddy just removed some rusty rockers and the spot weld drill does a cleaner job and a little quicker I think.

kinmont · Feb 9, 2021

Thanks, I have a line on a donor cab that im going to check out. Looks like you have the same issue but mine is much more rusted out.. luckily there are a few square body guys in the town I live that have offered to help!

Rust around windshield, what is the best option to repair?

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