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Opinions on how to fix?

D

Daves69Coupe

Member
I have about a 3/4" to a 1" hole in the top of my window frame on the driverside of the car. Whats the best way to go about fixing this? Its right in the corner so its gona be difficult to get a grinder in there to clean it up and weld in a patch panel. That or use some body filler or something.

Ill take a closer pic of the hole tonight and post
 
Instead of a grinder, use a dremel or other small tool with a grinder/sander type attachment. There are plenty of small tools that will allow you to clean, weld, and dress the area properly. Filler is not the way to go at all, plus you still need to clean the corrosion before applying filler.
 
in the top of my window frame on the driverside of the car
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Where?

The only item that could be categorized as a window "frame" is at the base of the window. To it attaches the door glass and the scissor arms of the door window regulator.

Is this where you have your rust spot?
 
"Daves69Coupe" said:
Top corner of the a-pillar where the roof and a-pillar meet.
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On the outside where it would visible? Or on the underside underneath the removed stainless steel roof side rail channel?

Either way the repair will be similar, but it'll be easier to fix if it's on the "top" side. Working on the underside of the A pillar/roof is usually more cumbersome.

Your best bet is to cut any/all rust completely out, fabricate a patch piece and weld it in. Grind your welds smooth and it'll be difficult to tell a repair was ever made.
 
it is not visible when the chrome trim is on. So ill dremel the bad area, make a patch and weld it in and grind the welds smooth and I should be set. Then Ill be able to put my window back in.
 
So this is on the windshield side? Same place where the lead filler was at the roof to a pillar seam? If so, that often cracks. While you are in there go ahead and weld that seam up some more before you add the filler to smooth it.
 
Cool, great pic, helps out a lot.

You're going to have to dig out the lead first. On one side mine was so loose it literally popped right now, on the other side I used a propane torch to soften it and then scrape it out. You could grind on it, but then you run the risk of cutting into the metal structure under the lead since there are a lot of angles there.

Once the lead is out, cut back the rust and weld in a patch. As stated before, you're going to want to have a solid seam there before you fill it again. You can use a high quality fiberglass filler there instead of lead.
 
"sigtauenus" said:
Once the lead is out, cut back the rust and weld in a patch. As stated before, you're going to want to have a solid seam there before you fill it again. You can use a high quality fiberglass filler there instead of lead.
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In place of lead, I used ALLMETAL filler. It can be used like plastic filler but it's stronger. It is difficult to get as smooth so I used plastic filler over the top for final coat and sanding. I like it because it isn't supposed to hold moisture like a plastic filler does so around an area that was rusty or is a seam, it's a little peace of mind.
http://www.handsontools.com/USC-14060-ALL-METAL-Premium-Aluminum-Filled-Filler-quart_p_10762.html
 
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