Rust Repair

spencer877

New member
So I got this van for a pretty sweet deal but it has some rust. I think the rust scared a lot of potential buyers off due to the high cost of paying a welder to fix (100hr). Lucky for me I am a welder, just haven't done any body work projects yet. The repair thats needed is around the windshield, I figured I was going to have to have to pop the windshield and the hood off just to make access to the rust damage. Has anyone done this project / or something similar? Anything I should know about taking the windshield off? Any and All Tips and Tricks appreciated.
 

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It would be the same as removing any automotive windshield. You can find tools to help if you google, but I'd probably just pay a glass shop to do it, probably won't take 30 minutes and you can talk to them about the welding job/ make sure they're going to be able to put the new one back in when you're ready.
 

Midwestdrifter

Engineer In Residence
There are a couple repair writeups floating about the forum.

One option is to find a donor, then cut out the sections you need, and flush weld them in. You will have several good sized holes I think. It may be expedient to section and remove the entire lower section of the window frame, and weld a complete replacement patch in. I am not sure if anyone sells a replacement panel/patch new for the area, so you may need to source one from a parts vehicle.

Another option by a user here, was to use kittyhair fillter (metal type). Not as long lasting, but if your holes are small enough.
 

Aqua Puttana

Poly - Thread Finder
... Has anyone done this project / or something similar? Anything I should know about taking the windshield off? Any and All Tips and Tricks appreciated.
Your rust looks worse than my 2004 did, but I never took a pick hammer to it.

My repair might buy some time if you want. I didn't remove the windshield. Repaired Fall 2012. The 2004 is still working fine. No problems. No leaks.

Windshield Rust Hack Job
https://sprinter-source.com/forum/showthread.php?t=36676

:cheers: vic
 

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