Mike@K-Tuned

I need some help from some experts.

My 1992 EG isn't getting any newer, and unfortunately I have a pretty frustrating problem. There is some rust building-up in the lower corners of the windshield frame that eventually blisters, pushes up and cracks my windshield. I have had this area repaired a couple times by a body shop but still the rust returns and the windshield cracks. This happens in approximately one year or so... The last time it was repaired some patches were welded in but just the other day it cracked again. Damn, there goes windshield number 3.

Anyway, I am contemplating removing the windshield and making the metal repairs myself.
I plan to cut-out and weld the affected corners and finish them off with some RUSTBULLET which supposedly stops rust permanantly.

Any opinions, experience or help with this problem is much appreciated.

Mike@K-Tuned

No help... Come on guys gimme a hand here.

katzenjammer84

Can you take pictures?

Mike@K-Tuned

I haven't removed the windshield just yet and it's going to have to wait until spring now...

Mike@K-Tuned

So nobody has repaired something similar to this?

FearTheH

iTrader: (5)

I've been doing auto refinishing for almost 10 year and have never encountered this type of situation...rustbullet is okay, but just remember nothing is permanent, especially in paint and body. My best suggestion is remove the windshield and any other possible obstructions. Take as much off in the areas as possible to see if you can locate the origin of the rust that the body shop has maybe missed and grind away the rust apply rustbullet as directions indicate on container. I don't suggest doing this until you have the means to have paint put over top of the surface promptly after the repair. I will ask around and see if I can find any other cases such as this. Hope this helps man, good luck with your fix, I know that's gotta be getting expensive. Holla at me if you need anything else.

same ol Steve

make sure you don't have a high spot in that area that might be causing a stress point breaking the w/s

Mike@K-Tuned

Thanks alot for your help. So do you suggest cutting and rewelding the area or just grinding? I'm beginning to think that the body shop just knocked away the majority of the rust and welded a plate over top.

That was something I thought about too... Thanks for mentioning it.

Mike@K-Tuned

I searched the internet a little, and here is the best pic I could find of an EG with the same problem. This is not my car, but the affected area is the same, only my problem is on the passenger side.

I remember seeing the problem area before the last repair and I think my cancer spot was about double the size. Anyway, here is the pic I found:

FearTheH

iTrader: (5)

Its honestly hard to tell how the body shop F'ed up or even missed some without looking at it, I would try grinding it away, I, personally, don't like welding anything in if it doesn't absoloutely need it. Like I said before tho, I'd remove fender, hood, windshield and anywhere there could be rust hiding that they may have missed. Grind all the rust away, and find some aluminum body filler, not sure about your location but here in Roanoke its only available at automotive paint supply stores. Apply that and do necessary steps to get paint on the area. I've definitely seen rust in that area, but never to where its breaking windshields. Although it wouldn't suprise me if your location has lots of icy weather and a lot of road salt, that stuff kills paint and causes nasty rust, especially around the windshield area and lower portions of the vehicle. I hope you get that fixed man, and if pics are possible, get em up. Good luck

Mike@K-Tuned

Does anyone have any recommendations for a good spray bomb primer to use on the repair? I have been using Dupont etching primer followed up by Dupont epoxy primer... I'm open to suggestions if there is something out there that works better.

Also has anyone used Rustbullet?

Mike@K-Tuned

OK guys, I really need some more help. My problem area is 100% like this:

I got lucky and found a member doing the same repair here on H-T. Experts, please give me your opinions on his repair.

Passenger corner, pretty nasty:











Driver side corner, I like how this side was done because there is a weld tying it in to the fender framerail:

JDMCRX

iTrader: (2)

Hey man nice pics

Yeah thats my car.

Here is the problem. From the getgo honda puts the car together spot welding it and so forth. Then they paint it and they miss all the spot welds under the windshield. Thats why they rust. If you look in my post. there is a channel like area between under the dash and the under windshield piece. Look under ur dash towards the windshield for rust.

Post some pics of ur car so i can see.

Mike@K-Tuned

Thanks for letting me post your pics and for the insight.

Bad news today, the windshield has now cracked from the lower passenger corner, up a little, and now runs all the way accross to the driver side. What a PITA, I wanted to wait a few weeks but it looks like surgery will be sooner than later...

FearTheH

iTrader: (5)

Nice pics of a repair, but the only problem I see is that the plates are welded over the existing problem. With something that bad, those sections need to be cut out and remade and welded in in place of the old removed sections. The problem with welding plates over top is that all the bare metal underneath isn't sealed off and will still get moisutre through the holes in the new plates. And rerust and you're back to square one. I would cut and weld in new pieces so you can get paint on ever piece of bare metal, and as far as the seams, see if you can get some honda bond seam sealer somewhere. And like I always say, do it once and do it right! Good luck big dog

Mike@K-Tuned

It looks to me like the rusted sections were cut out... I'm lost now... Maybe you could elaborate a little bit more...

FearTheH

iTrader: (5)

Negative, he grinded the rust away and welded plates over top. If your rust is as bad as that, cut infected areas out and make, or have made, plates to replace what you cut out. Weld them in and grind down welds. Fill if needed. Do not leave any metal exposed, or you will be doing all of this work again.

JDMCRX

iTrader: (2)

Wrong. I grinded surface rust left over oposing piece. If you look in my thread i had my camara on the opisits sides of the metal to check for any bubbling or rust.

All rust was cut out. Ever Piece was primed then tack welded at a slow rate not to burn off the primer. Then i actoned and cleaned and reprimered then sealed then painted.

If you look at the pics closely the piece that was rusted was spot weld cut out and new piece was made. When the car is done paint i will spray some rust proof on back side.

Ive done this repair on many cars that drive in canadian winter and 7 years later no rust.

Biggest problem even on a mint EG take off your wiper assembly shroud and use a light and a mirror and look under the windshield steel mount where it is spot welded accross the whole front of the car. Let me know how much primer is there. There will be little primer and No base paint at all. This is a common problem with the honda's even my acura 1.6EL made in 2000 had the same thing. Its never seen winter and i can see the light coat of primer under this lip.

JDMCRX

iTrader: (2)

Here is the post on another forum since HT blows serious *****.

http://nwp4life.zeroforum.com/zerothread?id=22182

FearTheH

iTrader: (5)

so definitely just got on HT from my pc instead of blackberry....wow those pics are a lot bigger than ive been seein! jeez, i couldnt tell that you cut that piece out. looks good

Mike@K-Tuned

Thanks for clearing that up guys, I was positive I saw that the rusted sections were removed. I think my repair will be very similar.

JDMCRX

iTrader: (2)

Take all the calkin off the car with a small wire wheel or screw driver post some pics. Look on booth side. If the line of rust stops here go passed it atleast half a inch. Ud be suprised whats under it . Post some pics.

Mike@K-Tuned

Sounds good to me. Thanks

Mike@K-Tuned

Any more input on the repair I posted? Feedback is helpful because I plan to repair my problem in a very similar way.

Has anyone on here used Rustbullet? Any thoughts?