I have a beater trail rig that's light khaki metallic. At some point in its lifetime, one of the previous owners must have replaced the windshield frame & glass from a black TJ.
Earlier this summer, I found a local add for someone getting rid of a khaki TJ for $500. Granted there were no doors, no tailgate, no interior, no motor/trans, & frame was rotted, but it did have some good parts to strip off. The windshield glass was good but the bottom of the frame had the usual signs of New England rust/rot. Having stared at the windhshield frame over a few beers, I figured why not try to remove the cancer and attempt to replace the bottom with a new piece of metal. This way, I didn't have to search for another frame or frame/glass which might have required paint.
First, the windshield interior weatherstripping will have to be peeled back at the bottom and about 6" up each side. It appears that the windshield frame is two pieces of stamped steel (I think 18 gauge). The lower interior "strip" of metal was cut on both sides and is spot-welded, at the top, to the outer frames' piece of metal. At the very bottom of the frame, both pieces are crimped together creating the leading lower edge of the entire frame. You'll need to carefully drill the spot welds mentioned above. I emphasize "carefully" as the bottom edge of the glass is behind the outer frame edge. Drilling through both pieces of metal, one could easily hit the inside of the glass. Next, take a small prybar and fold the rolled edge of the outer piece of metal, crimping the remaining interior "strip". From here, whatever cancer can be removed. Once this piece is removed, you can carefully examine the steel of the exterior frame as this was concealed. My frame was decent so I decided to continue with the repair.
Having gone to my local metal fab shop, I had them bend me a 52" piece of 18 gauge to the profile that matched the interior "strip". I cut the piece to fit the frame as depicted in the photo, drilled some small holes to weld locations that once had spot welds, and also welded the ends of the strip to the frame.
Using some 6" duct-bill pliers, I crimped the lower seam back together followed by some $15 body panel seam sealer from Amazon to help with adhesion and fill some of the spot welds.
https://www.amazon.com/dp/B0BX1YFHYC?tag=wranglerorg-20
Now, if your frame is flame red, black, etc... I'm sure you can run to your local Autozone, O-Reily's, or whatever to grab a $20 can of dupli-color perfect match but for Khaki (PJC), luckily I had a half a can of Automotive touchup (originally $40 just for the base color).
After the repair was painted, some $15 windshield weatherstrip adhesive from amazon to re-attach the weatherstripping pulled earlier.
https://www.amazon.com/dp/B0FPX8G2KC?tag=wranglerorg-20
Earlier this summer, I found a local add for someone getting rid of a khaki TJ for $500. Granted there were no doors, no tailgate, no interior, no motor/trans, & frame was rotted, but it did have some good parts to strip off. The windshield glass was good but the bottom of the frame had the usual signs of New England rust/rot. Having stared at the windhshield frame over a few beers, I figured why not try to remove the cancer and attempt to replace the bottom with a new piece of metal. This way, I didn't have to search for another frame or frame/glass which might have required paint.
First, the windshield interior weatherstripping will have to be peeled back at the bottom and about 6" up each side. It appears that the windshield frame is two pieces of stamped steel (I think 18 gauge). The lower interior "strip" of metal was cut on both sides and is spot-welded, at the top, to the outer frames' piece of metal. At the very bottom of the frame, both pieces are crimped together creating the leading lower edge of the entire frame. You'll need to carefully drill the spot welds mentioned above. I emphasize "carefully" as the bottom edge of the glass is behind the outer frame edge. Drilling through both pieces of metal, one could easily hit the inside of the glass. Next, take a small prybar and fold the rolled edge of the outer piece of metal, crimping the remaining interior "strip". From here, whatever cancer can be removed. Once this piece is removed, you can carefully examine the steel of the exterior frame as this was concealed. My frame was decent so I decided to continue with the repair.
Having gone to my local metal fab shop, I had them bend me a 52" piece of 18 gauge to the profile that matched the interior "strip". I cut the piece to fit the frame as depicted in the photo, drilled some small holes to weld locations that once had spot welds, and also welded the ends of the strip to the frame.
Using some 6" duct-bill pliers, I crimped the lower seam back together followed by some $15 body panel seam sealer from Amazon to help with adhesion and fill some of the spot welds.
https://www.amazon.com/dp/B0BX1YFHYC?tag=wranglerorg-20
Now, if your frame is flame red, black, etc... I'm sure you can run to your local Autozone, O-Reily's, or whatever to grab a $20 can of dupli-color perfect match but for Khaki (PJC), luckily I had a half a can of Automotive touchup (originally $40 just for the base color).
After the repair was painted, some $15 windshield weatherstrip adhesive from amazon to re-attach the weatherstripping pulled earlier.
https://www.amazon.com/dp/B0FPX8G2KC?tag=wranglerorg-20
