This topic originated here:

http://www.bonnevilleclub.com/forum/...ic.php?t=62341

The windshield guys came today to install a new windshield. Boy was I in for a big surprise once the old one came off. I had them remove the old windshield and will call them back to install the new one once I address this mess. Check out these photos:

Driver'* side:





Center:


Passenger side:


The installers told me this occured due to a poor install from the last installers (my windshield wasn't original, apparently). There wasn't enough adhesive at those points and the water pooled in those locations....and sat there....and rusted the inset frame.

What is the correct way to fix this? I have my initial thoughts. Wire wheel it all down to fresh metal/primer. Mask off all surrounding areas (including the roof) and go at with about 8 coats of black Rust Oleum.

Once that'* done I'll call them back to get the new winshield installed. Luckily I have another car to drive so the Bonnie can sit for as long as necessary. Plus it'* in my garage.

Thoughts?

I just had my wife'* windshield replaced and the only reason it was being replaced is because the rust got so bad underneath the windshield that it cracked in 3 different locations. The way they solved it is by sanding it down filling it in with fiberglass. I found that odd, so while it was being done, I phoned another glass place and they told me they would have done the same thing.

Not sure if that info helps.

man i hope mines not like that, cuz i know mines not factory :?

Yeah, I would agree, wire wheel/sand it and do what you can to remove the rust. Then coat it with Eastwood Rust Encapsulator, then paint.

If it wasn't sealed correctly (like mine) then it more than likely is...or will become that way if not corrected soon.

Fiberglass filler is a good idea. If the remaining metal is very thin I'll likely go that route.

Wow whats with these Bonnes and retaining water in places? My door moulding retains water after it rains. The car can be almost dried and when I open the door, I get a small waterfall. Same for the rear trunk area where the lip of the lid comes down. That little plastic runner piece? Holds water.

As far as my windshield, It was replaced new not too long before I bought the car, so no pitted glass

What you can probably do is bring it down to bare metal, and see if there are any little holes from the rust. If there is, you might want to skim coat it with Bondo then sand smooth, prime and paint.

my 95 was the same way, except worse, the rust was coming up onto the finish... visible with the windshield still there...

If you look closely at the first pic the paint is starting to bubble on the roof. It was visible with the windshield intact.

Oh my god. We both have the same year and yours has rusted, the gas door rusted already, now this. my car hasn't even had one speck of rust on it. It doesn't retain water, etc.

The gas door is really bad. I have a new one on the garage shelf that needs to be primed and painted. I've just been too lazy in that department...

My door seals used to leak too. I fixed all four of them already by adding in a chunk of weatherstripping. Those are all tight.

I'm going to use a wire wheel on the affected windshield rust areas tonight. If the metal is decent underneath I'll apply several coats of black Rust Oleum. Otherwise I'll have to use some body filler.