Thought Id show the board some pics of my amateur windshield rust repair. I havent finished the drivers side yet but Ill post pictures of that and the dash when its painted. Mind you this is the second sheet metal rust repair job Ive ever done, and it was done with very basic tools.

Heres how it looked, I knew there were holes as it leaked on the passenger side.

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0460.jpg

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0462.jpg



Was a little bigger than expected

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0491.jpg



Ground it down a bit to find good steel

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0502.jpg


Got some 22 guage steel from home depot and some metal shears. I used my bench vise and a hammer to rough shape this, then trimmed it to the hole I cut.

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0521.jpg



Trimmed until it fit good then tack welded all around it and ground it down.

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0596.jpg



Mixed up some bondo and applied it, now im stuck doing the boring sanding!

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0625.jpg

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0624.jpg

And you did a bang up job! well done!

I second that, nice job:thumbsup:

Thanks!

I also took advantage of everything being disassembled to turn this:

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0495.jpg

Into:

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0597.jpg

nice job-sometimes i make it up in a couple pieces, weld them together
nice job on the dash too-the detail pays off in the long run

Nice job well done:thumbsup:

looks good.

Sweeet work bro!!!!

VERY nice work, Dan!!!!:thumbsup:

Nice job.

On a side note, you might want to remove the filler on the actual channel area where the windshield adhesive goes. Regardless of if you use urethane or butyl tape you don't want filler between metal and the adhesive agent, its asking for problems IF you were to get into an accident...Eric

Thanks again guys!

sevt_chevelle Good point, I have been meaning to look up what type of sealer to use and all the tips that go with it.

What paint did you use on the cover, it turned out great. I also have the same problem on my 69 but it's isn't that bad, you did a great job with and gave me hope.

Lookin good.

Great job. Just goes to show you, you don't need a ton of experience to do much of this work, just common sense, a bit of knowledge and attention to detail. That dash looks great.

Heres an update, this side was a little more time consuming as the the steel was a bit thinner and I kept burning through, it is solid and Im sure that it will last as long as I want it to.

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0464.jpg

http://i128.photobucket.com/albums/p182/12LbMalibu/IMG_0643.jpg


http://i128.photobucket.com/albums/p182/12LbMalibu/IMG_0678.jpg

Good job on the top of the cowl Dan! Mine had some holes down inside the bottom of the cowl, where the birds & mice nested. Could have leaked onto the left foot.

Are you going to use self etch primer or just epoxy primer?

Ive got a thing of Summit epoxy primer. What I need to know is where to get the right 0% gloss to paint this portion of the dash.

Very nice, very nice. :thumbsup:

Well heres an update. I ended up using SEM self ethcing primer, and SEM Trim Black for the color.

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0777.jpg

http://i128.photobucket.com/albums/p182/12LbMalibu/2010%20mini%20resto/IMG_0783.jpg

i like to use a paint with a hardner on the area where the windshield gets taped-the paint store near me can put it in spray cans, with a plunger on the bottom that you hit to release the hardner when your ready-i have it mixed close to the color im painting the car
only problem is you have to use it all pretty soon
or you can use those little prevel sprayers and mix your own
your looking good

Very nice work.
Ray

i just redid my 68 dash gauges and only cleaned the bezel, ur bezel looks great. ur bezel will be my goal -in burgundy though.

that instrument cluster will look great, but I see no difference in the shoes ha-ha.
nice repair.

Nice metal working and nice re-do on the dash. Bravo.

I woulda cut that out

how did you change the dash to black? is that just paint?