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69 Blazer Rusted out windshield frame repair/replacement(Glass Installed 10-29-10)

I've got at least that much in my transmission tunnel cover.....I feel you dawg.

:waytogo:



:usaflag:
 
I'll bet it had holes in the top of the frame....rain kept getting in and couldn't drain down the a-pillars to escape so it just started eating it's way through from the inside.


:usaflag:
 
I do believe you hit the nail on the head. The soft top was screwed in and the screws were not siliconed or anything also there were no door rubber thingys on the 3 hole mounting faces (hence I asked what those holes were for) and no plugs/bolts in the holes where the hard top attached. That and I live on the coast so salt air and el-rustola
 
OK I'm back at it again. Since my last post my work truck had a case of spontaneous combustion, one of my workers put my Bobcat on the side of a nice hill and then to top that off 2 of the 6 new nuts I welded on the windshield frame for the visors Galled and I had to cut & grind them and start again.(this time I put plenty of anti-seize) Alright enough with the Wa Wa Wa's. Got everything sized up yesterday and after looking at it for a while decided to not go with those solid brace things inside the centers so I cut some flat pieces and used sheet metal screws to tempoarly secure them on untill the final welding. This also helped me to align the posts. Test fit the rubber for sizing, seemed to be ok

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that seems like it'll work too. I'm curious to see how the welding goes. Are you going to installed the windshield beforehand?
 
I'm not going to actually install it but I've been using a cardboard one to size while I've been doing the work and the rubber seems to fit without any extra. I am going to use the glass on the final mock up before welding but I'll need to coax an extra person for that.
 
More pictures. Got insides coated with rust converter 2 days dry time then coated with (Rustoleum) cold galvanizing compound 1 day dry time. test fit one more time then started to seal that sucker up. Stitch welding takes forever and then the 1st grinding. The holes are where the old metal from the original metal was kinda thin I'll just drop the amperage to fill in those spots. It's getting so close I can almost see a actual windshield going into that gaping hole that was once cancer ridden.

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Got it sealed up last weekend fairly well. While test fitting one last time I decided to put some backer metal in the areas where the bigger gaps were.5-24-09 005.jpg

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Decided it was time to commit so the first tack welds commenced. It felt right so I finished them off.5-30-09 001.jpg5-30-09 006.jpg

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THat looks great. I will be doing the same type of thing shortly with mine. It looks solid but feels very weak. It's great to see you tackling this as it give me courage to try it. Keep up with the pictures as I'll be watching this one closely.
 
I Think I'm finished, except for some final touches and a wee bit-o-bondo. but that will be later on. Now I can move on to getting the tub off the frame since the tub is structurally sound(so to speak). These pictures are before primer.

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So today I took the plunge and what was once 1 is now 2. Body removal not a new thing to be done just a big step for me none the less. It's nice to know a few guys who will work for beer & subway.

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Good job, i bet it feels good to have that weight off your shoulders. That has been the best feeling on my build. You get so caught up in certain areas of the project that it seems that you are getting nowhere, but then you get past it and it feels sooooo good.
 
That had to feel good getting that windshield in.:woot:

I'm sure that the repair, as far as fitment issues were always in the back of your head until now.

Congrats and good job.:waytogo:




And.......I also like the Halloween resi clamps, they are very festive.:eek1::D

-Mike
 
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