Repairing metal under windshield on '66

[bluecab]

Doc, Thanks.
I guess the reason these areas rust is because there is a gap at the top that lets condensation run down into there.
I asked the question as when I laid out the patch and put a strait edge on it top to bottom, I was surprised the angle of the bottom was so far off.
Some of the rust was back past the lip where the bend is, thus the messy weld. This will need some further fill welding.
It does look much more wavy in the photo than it really is.I'll probably have to use some epoxy filler to finish it off nice.
These windows were put in with a butyl strip originally. These may still be available, but I'm going to use a Sika polyurethane to get the height right as well as for safety.
You're right about the improvement in materials there!
Anyway, thanks for the help, It's really appreciated
Here's another shot that looks "less" wavy Ha ha

[bluecab]

Forgot to mention that I will be trial fitting the windshield.
I think thats a necessity where the original metal did not leave much to go by.
There are a few interesting threads on the pro touring site where guys are flush mounting there glass as part of the rebuild process. I need to read more on this...

David

[Doc Hubler]

Here's some pictures of the windshield area. Your repair doesn't have the lip for bottom of windshield. Not sure it matters and not sure that really has to be perfectly smooth. In fact, it doesn't as the windshield sealer makes up for the minor gaps. Hope this helps a little. I should have wiped the dust off before I did these pictures. Also, that area is painted glossy, but will be satin. Essentially didn't have to do any repairs of any of this area, thankfully.

[bluecab]

Ahhh. None of the other photos have shown the lip and angle at the windshield base.
There was no trace of the lip left on my car. I wonder if the windshield seating area at the bottom has a steep enough angle to allow the windshield to sit flat.
I was using a strait edge from the top lip to the bottom to see the seating angle at the base. So my question is would the windshield would sit flat against that area when installed?

[Doc Hubler]

Yes, windshield sits flat against area above the lip. That's where it seats/seals to the body.

[Twilight Fenrir]

I've never seen that lip either, actually o.o

When I did my repair, as documented at the start of this thread, I kind of just attached it at the top, and at the bottom. Had no idea there was supposed to be a ledge... The guy who put in my window had these little bumpers he set in place to keep it held up, and it went perfectly. There hasn't been any leaks in the couple years since I did this, so the lack of ledge isn't critical.

Also, don't have to worry AT ALL about the waviness in the metal. The adhesive the guy used was applied in a.... hmm... well, it looked like if you took the sharp end of a pencil, and cut it off about an inch or so down. So, it was standing upright about an inch, even though it was only about half an inch thick. Slight waves would not affect it AT ALL.

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