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Windshield rust repair or buy a new one?

toximus

TJ Addict
Supporting Member
Mar 29, 2018
2,243
Northern WI
I folded the windshield down to expose a rust problem that I kinda knew I'd find.

Has anyone had success with the repair kits or should I bite the bullet and buy a new frame?

IMG_20181231_133334.jpg
 

Chris

Administrator
Staff Member
Sep 28, 2015
38,083
Salem, Oregon
How much can you find a new frame for? That would be the determining factor for me. It a new frame is cheap enough, it’s more cost effective to just buy a new frame. I am of course counting time as labor, and therefore of some value.
 

jodomcfrodo

TJ Addict
Supporting Member
Feb 24, 2016
1,352
Evanston, IL, United States
Is that area very visible? Will a repair be an eyesore? Do the windshield frames rot out from the inside just like the frames do on TJ’s? If you don’t foresee any more problems with that windshield frame in the future, it’d seem like cutting out that section of the windshield frame and welding / using seam sealer to put a new piece of steel in would be a good enough repair that wouldn’t take a lot of time or money to do.
 
OP
toximus

toximus

TJ Addict
Supporting Member
Mar 29, 2018
2,243
Northern WI
How much can you find a new frame for? That would be the determining factor for me. It a new frame is cheap enough, it’s more cost effective to just buy a new frame. I am of course counting time as labor, and therefore of some value.
$585 for a clean red OEM frame on eBay. $79 for the repair kit + time + paint.

Daveys site isn't loading for me right now.
 
OP
toximus

toximus

TJ Addict
Supporting Member
Mar 29, 2018
2,243
Northern WI
Is that area very visible? Will a repair be an eyesore? Do the windshield frames rot out from the inside just like the frames do on TJ’s? If you don’t foresee any more problems with that windshield frame in the future, it’d seem like cutting out that section of the windshield frame and welding / using seam sealer to put a new piece of steel in would be a good enough repair that wouldn’t take a lot of time or money to do.
That's what the repair kit looks to be. It did rust from the inside out. The other side is rusted but not as bad. There's no place for the water to drain since the seal holds it in.
 
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toximus

toximus

TJ Addict
Supporting Member
Mar 29, 2018
2,243
Northern WI
Are there rust inside the corners of the frame? The area that that new piece doesn't replace?

That might be the determining factor for me. I don't know what the rest of that frame looks like inside of it.
That's a good point. What I can see looks fairly clean at least nothing a little sanding and paint couldn't fix. I'd have to cut it open to be sure.
 

Chris

Administrator
Staff Member
Sep 28, 2015
38,083
Salem, Oregon
That's a good point. What I can see looks fairly clean at least nothing a little sanding and paint couldn't fix. I'd have to cut it open to be sure.
That's where I would start. Cut it open and go from there. If there's rust all over the inside, that would be the tipping point for me to just buy a new windshield frame.
 

Boinked

TJ Addict
Jul 7, 2018
2,553
Mesa,az
$585 for a clean red OEM frame on eBay. $79 for the repair kit + time + paint.

Daveys site isn't loading for me right now.
Red is one of the more expensive paint colors. Due to the pigment used. Might want to price the paint.

I paid well over 300 for a small Can to paint my wifes Harley.
 
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toximus

toximus

TJ Addict
Supporting Member
Mar 29, 2018
2,243
Northern WI
Does anyone have a suggestion for replacement glass and glass seal/molding? If it's all the same, my insurance actually owes me for the chipped glass and I'll just have them have them send whoever out to fit the glass once I'm done.
 
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RussTJ

TJ Enthusiast
Nov 22, 2017
434
Bridgewater, MA, USA
I had the same issue and bought a frame from Crown for $120 last fall. I had it painted, along with a full set of doors, at Maaco. My insurance covered the new windshield.
 

BlackSheep

Member
Dec 8, 2018
47
Greenville, SC
Unless you have some type of aftermarket sport bar that reinforces your A pillar - that rusty beast is the base of your A pillar. For the cost of a used one (I paid $250 at my local TJ recycler for one that is not color matched), it's worth the peace of mind.

My original windshield was maybe about or slightly worse than what you show. I found the rust when I lowered my windshield to install the Smittybilt sport bar kit. I didn't think twice about replacing the windshield even with the addition of the sport bar kit.
 
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OP
toximus

toximus

TJ Addict
Supporting Member
Mar 29, 2018
2,243
Northern WI
Unless you have some type of aftermarket sport bar that reinforces your A pillar - that rusty beast is the base of your A pillar. For the cost of a used one (I paid $250 at my local TJ recycler for one that is not color matched), it's worth the peace of mind.

My original windshield was maybe about or slightly worse than what you show. I found the rust when I lowered my windshield to install the Smittybilt sport bar kit. I didn't think twice about replacing the windshield even with the addition of the sport bar kit.
That's why I lowered the windshield too. I'm building a cage.
 
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KCsTJ

TJ student
Supporting Member
@KCsTJ here is a thread for you to follow.
Thanks @b0xcar , yes I am following closely because I found this little surprise after I bought my 05 Sport. It was very well hidden.
It was painted over. I found it while wiping off some dust after wheeling.
My finger went right thru.... ugh
20181231_153117.jpg

Apparently a bad seal, and for a long time no doubt. :-/
 
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OP
toximus

toximus

TJ Addict
Supporting Member
Mar 29, 2018
2,243
Northern WI
A friend who used to repair glass stopped over and helped me remove the glass. Unfortunately, we had to use a knife to cut through the urethane which also scratched the paint around the window. With the window out I can see that there's no way the water entered around the glass. I haven't figured out yet how the water entered the frame.

I tried calling Davey's a few times but the line just rings.
 
OP
toximus

toximus

TJ Addict
Supporting Member
Mar 29, 2018
2,243
Northern WI
I opened it up and the metal is decent except for this one spot.

IMG_20181231_180939.jpg


Here's a picture into the corner:

IMG_20181231_175411.jpg


Yes, there is rust. However I don't see the need to replace the entire frame just yet and pay a lot for the part. I'm going to clean it up and bandaid the windshield frame together to buy more time and keep my eye open for a new one. To make things even easier on me I'll probably just paint it right on the Jeep too.

I might take a look at metal brakes so I can bend up my own repair piece.
 
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