Fixing rust at the base of a windshield.

It looks like I am buying a 84 Volvo 240 wagon. It has some rust throught the body. Eventually it will likely need to be "rebodied" with a cheap donor. Aside from the doors and back hatch it seems pretty decent. The only part that really bothers me is the rust beneath the windshield. It is through in a couple spots.

From what I understand this is pretty common on the 240s but I have yet to find a good thread on repair. I know pulling the windshield is in order but what is the best way to repair. Just throw in some bits of steel after I cut away the old stuff? Any place beneath this spot I need to look for rust?

The interior is clean and doesnt smell as though water has been sitting in it. The car has a professional 5.0 conversion and is great in every other aspect. So buy another is not a real good suggestion at this point.

Thanks,

Greg

I had this done to our A2 VW Jetta, the base was bubbling pretty badly and at the time I planned on keeping it for awhile. I paid a shop to do it for me. Once the windshield was out, it was worse than either of us expected (and I'm not an optimist when it comes to rust). What he wound up doing was using epoxy to fill and form the missing areas (I'm assuming some sort of fiberglass screen for backing). Stronger than body filler and impervious to water, plus it's easy to shape the multiple contours needed there. Looked fantastic when finished and painted but sold the car within a year so can't comment on the longevity.

I just did a bunch of rust repair on the Mazda including some around the rear hatch. I cut out the bad spots and bent and welded in new metal. It was a PITA, but is as good as new. Hopefully I will do a better job of keeping the debris from building up than the PO did and won't have to do it again.

on my last camaro i pulled the glass, cut it all out, and welded in new parts that i formed to it.

I guess the extent of the rust is yet to be seen. I'll formulate a plan of action once the windshield it out. As always I want to do it as cheap as possible especially since the rest of the car will still have some rust. Maybe I just need to find a cheap donor.

I'd check if there is a repair panel available and use that if the shape is complicated and/or the holes are rather large.

While fibreglassing would probably work I'd be a bit wary as it won't necessarily do much for the shell's integrity if you manage to park it on its roof.

Greg,

I have done this many times. The only right way to do this to pull the windshield out, wire brush wheel the entire area and cut out old and then weld in new metal. You will need to be especially careful to get the contour of the windshield the same as original, or the windshield either won't fit or will leak. Then get a new winhshield gasket or bond in kit. A windshield pro will put a windshield in for less than $100 (go see Tom Prescott at the Body Werks), as you are local.