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post #31 of (permalink) Old 09-04-2013, 08:08 AM
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Join Date: May 2008
Location: Madison, Wisconsin
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Since you are planning on keeping the car. the best way to fix this is to cut that rust out and then weld in a new piece of metal. It is not difficult but will require you to remove the windscreen and have access to a MIG welder and some 1mm sheet metal and a grinder.

Once the wind screen is out, you can address any other rust issues around the perimeter. Dealing with these issues now will prevent water from getting into other areas that would be much more difficult to fix later.
If you are not up to doing this yourself, I would have it done by a reputable body repair shop.

It will be easy to then take the finish down to bare metal and then prime the entire perimeter that supports the windscreen since everything will be out of the way. When that is finished, you can sleep nights and not have to worry about future rusts issues in that area. All of the surfaces in this area are covered by the gasket or trim pieces so they really do not have to match the rest of the car color.

74 Spider - Completed; Tuning Weber's
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