Just shooting in the dark here, I don’t have high hopes than any folks here are experts in body work BUT:

So I’m pretty sure my car got a botched windshield replacement as some point. I’ve attached pictures of the roof right above the windshield. The pictures show the rust spots from left to right looking at the car from the front.

First, I’m just wondering if this is possible to fix, like is this a case of ignoring the rust and running the car until it can’t go anymore or if this is worth doing something. If this isn’t too much for a body shop to do, I’m willing to get the work done

Second, what do you guys think the cost of repair would be for repairing the rust, whatever options there are. I’m thinking this would be about $3000 to get the body work done and then I could do some touch up sealing and painting.

Here are the pictures left to right:

 

What you see is about 10% of rust hiding behind the glass. It has to come out at that point can come up with an estimate. I've done this type of repair several times there were holes in the corners by the A-piller. Most body shops 100% do not do rust repair of any kind best of luck finding one that does.

BTW that rust happens because glass installers scrap away the old sealant and damage the paint underneath. A car with original glass will never have rust issues under the glass no matter how old the car is.

 

Hi thanks for replying. You said you’ve done this work before, on your own or through some kind of shop/service? Asking because you said no body shop does rust repair, so where if anywhere, could I go to get this done?

If I could remove the glass on my own and re-install, I would and try to find a welder friend to patch the holes, but all that sounds sketch to do on my own.

I was hoping there was light at the end of the tunnel with this car as being able to repair the rust would’ve gave me the green light on re-painting the rest of the car, doing the LS brake upgrade, and then hopefully forced induction stuff as I LOVE the GS and was really hoping to make this basically top shape.

 

Look into body shops or individuals that restore cars those are the guys that do the hard stuff including rust repair. Regular body shops are drilling out spot welds and replacing panels all day rust repair is not their thing.

I did the repairs myself. Quick version is remove windshield, remove rust, treat with phosphoric acid. Paint with Rust Bullet. I did patch in small pieces of metal (brazing). You don't have to can put in some mesh then seal with POR-15 patch. Follow up with Rust Bullet (best rust paint there is I've tried them all). Not a 100% permanent repair but it will last around 8-10 years before rust starts again. By the time you see visible rust you probably won't care.

Ideally. Problem is if you remove the glass then driving the car anywhere is an issue. There might not be rust through it's hard to say. I have seen cars in Hawaii with extensive rust problems that you don't normally see in lower humidly climates. Rust that formed from the inside out.
I won't sugar coat it this repair is not easy especially when pulling the glass without damaging it. I removed the entire dash so there was no chance I'd cut into it, but I'm not a glass expert quite the opposite.

 

Hey sorry for the late response but I think I'm gonna try the mesh and POR-15 patch as there's a tutorial on repairing fenders using that method by ChrisFix. I just need to figure out how I'm gonna go about removing and re-installing the windshield. I'll keep the dashboard removal tip in my pocket.

Hawai'i definitely doesn't help when it comes to keeping rust away, especially when my car is parked out under the weather for half of the year. If I manage to repair the rust, hopefully I remember to update this thread on the results.

Thanks for the input!

 

I can't stress this enough don't use POR-15 paint on anything but rusty metal if you do the paint will eventually come off in sheets. POR-15 patch works effectively in situations where it is pressed into a mesh, or conforms around holes in the metal. Use Rust Bullet with the accelerator (called Rapid Fire) it helps the paint cure with less bubbles. Buy the smallest cans available as soon as you open the container the paint will cure even if you seal the can again. Putting in in the fridge helps (don't freeze it).

POR-15 and Rust Bullet is nasty stuff if you get it on your hands and it dries you'll be wearing it for awhile.

Looking at your picture again pretty sure I could stick a screwdriver right through the metal in some places.

 

No actions yet but I’ve decided to enlist the help of a friend when the time comes, to weld in new metal after I have the windshield removed and I grind and cut out the rust.