Windshield rust repair or buy a new one?
- Thread starter toximus
- Start date
I found a windshield from a guy who parts wranglers locally. It was the right color and had glass, for 250 bucks. The rub is that its from a 98 and I have an 04. The interior trim is different. Easy change to make to the frame to install then newer trim. When I was looking the earlier windshields were MUCH easier to find used and much less expensive than the later models.
OP
I just started dabbling into POR 15. That stuffs the real deal. I was blown away. You can get it in gloss or semi gloss. It loves to bond to rust after scale is removed, but i also found it to bond very well with new or clean metal. I use brake clean before applying it to new and clean material. at 26 bucks a pint on amazon, this is more than enough for small repairs. Its crazy how a little goes such a long way. You can prime it while tacky and spray a nice paint over it. I like that new rustoleum 2x acrylic paint.
OP
Nope. Body panel adhesive. I started using this stuff a few months ago and I ended up really liking how easy it is to use and it seals at the same time to (hopefully) prevent future rust from forming in pockets. The bonding strength of it is amazing.
OP
I opened this thread hoping to learn how it is a windshield rusts. Imagine my disappointment to find you referring to the frame...
Sorry to disappoint!
OP
I have had mixed results with POR-15 even with lengthy prep. If you read my first build thread and the start of my new build thread you can see my experience.
Por15 is not as great as some think. I used it on my tj after wire wheeling and it rusted through again.
Also used it on my ford escort wagon. No sanding just knocked loose rust off. Still rusted through.
Also used it on my ford escort wagon. No sanding just knocked loose rust off. Still rusted through.
I'm giving the Rustoleum Rust Reformer (RRR) a try because of this study:
https://www.ncptt.nps.gov/wp-content/uploads/metal-paper-88.pdf
POR-15 is a phosphoric acid based product like the Ospho in the study. I have no experience with it, so I can't comment on how well it works. From some other reading I did on this subject, the tannic acid based products like the RRR do seem to fair well in tests, like the study above. RRR also contains an acrylic vinylidene chloride copolymer additive that helps create a nice paintable coating.
So far, I've used it on my axles, skid plates, and several other spots. I cleaned, sanded, and prepped the areas the best I could before hitting with the RRR for a few coats. It cures to a nice flat black. After that, I shoot it again with a few light coats of high-temp flat black anti-rust rattle can paint. It is very easy to work with. Will it do well? Will it hold up? Who knows, but I will find out over the years! You can pick it up locally for cheap (~$5-6 can) and it isn't as nasty to work with as POR-15. It seems like a good fit for some jobs, but perhaps not all. My guess is that, with any of these types of products, you'll still have to examine and keep after it year after year. I just hope this at least makes life easier doing it.
https://www.ncptt.nps.gov/wp-content/uploads/metal-paper-88.pdf
POR-15 is a phosphoric acid based product like the Ospho in the study. I have no experience with it, so I can't comment on how well it works. From some other reading I did on this subject, the tannic acid based products like the RRR do seem to fair well in tests, like the study above. RRR also contains an acrylic vinylidene chloride copolymer additive that helps create a nice paintable coating.
So far, I've used it on my axles, skid plates, and several other spots. I cleaned, sanded, and prepped the areas the best I could before hitting with the RRR for a few coats. It cures to a nice flat black. After that, I shoot it again with a few light coats of high-temp flat black anti-rust rattle can paint. It is very easy to work with. Will it do well? Will it hold up? Who knows, but I will find out over the years! You can pick it up locally for cheap (~$5-6 can) and it isn't as nasty to work with as POR-15. It seems like a good fit for some jobs, but perhaps not all. My guess is that, with any of these types of products, you'll still have to examine and keep after it year after year. I just hope this at least makes life easier doing it.
I picked up a few cans of the same, and will use it as needed. Like you, I have no experience with it, but figure you gotta start somewhere, so let's give it a go. Here's hoping...
OP
If you're dealing with surface rust, a rust converter will have more favorable results than if you have rot.
My expectations are definitely limited to dealing with mild surface rust/pitting.
@toximus Do we have a sense of how common of a problem the windshield rot is? I'm definitely pulling mine off in the Spring to take a closer look!
Yeah, I am definitely keeping my expectations low, and for surface rust only (like axles, skid plates etc). After I had everything degreased, sanded, converted (if applicable), and painted, I let it cure for a a few months over the hot summer. Then, in the late Fall, I applied Fluid Film copiously and meticulously over the entire underbody, inside the frame, and in any nook and cranny I could penetrate with the stuff. I plan to repeat this procedure in general year after year, and over time hopefully learn which techniques and products work best for select areas. We can only do what we can do, since we all know "Rust Never Sleeps"!
Yeah, I am definitely keeping my expectations low, and for surface rust only (like axles, skid plates etc). After I had everything degreased, sanded, converted (if applicable), and painted, I let it cure for a a few months over the hot summer. Then, in the late Fall, I applied Fluid Film copiously and meticulously over the entire underbody, inside the frame, and in any nook and cranny I could penetrate with the stuff. I plan to repeat this procedure in general year after year, and over time hopefully learn which techniques and products work best for select areas. We can only do what we can do, since we all know "Rust Never Sleeps"!
I don't drive mine in the winter...Hasn't seen salt in the two years I've owned her. Still rusting through. I wirewheeled all the loose stuff, cleaned and degreased, then put two coats on. For the effort I expended (not much) I think its ok. Just don't be surprised to see it come back. Granted, the only way I'm going to stop the rust on my tub is to cut it all out so...It starts in the pinch welds, and once its there, you can get rid of it unless you cut it and start over. I bought a welder, so eventually my tub is coming off, and I'll fix it. The passenger side torque box is going and the rear wheel well is perforated. I don't feel like painting it yet, so I'll just run it until it becomes an eyesore.
I just checked out your build thread and was looking at the oil pan pics. Yikes! I will be curious to see how your axles hold up as it looks like you did a great job. I am lucky that my TJ came from outside the Midwest. Mine will see light duty in the Winter since I bought it for the 4WD. I'll be driving my other car a lot of the time (especially on those after-melt days where you just drive through tons of brine water). We have been lucky so far this year with the snow and ice (as have you guys up in GR). They haven't used hardly any salt of the roads so far, and when they have, we have had some good rain to wash it off. However, that looks like it might start to change after yesterday when we finally had ~2" of snow. We really want to move out west to the desert in 4 years or so. Hopefully we do and I can keep the rust at bay until then! If mine ever starts to concern me, I'll sell it before it gets too bad and pickup something better once I get out there.
OP
I'm not sure how common it is. I don't think we hear about it as much as it happens because people are more concerned with their frames (rightfully so) that probably rust through before the windshield becomes too much of a problem. I wish I had taken a picture with the windshield up to show, but I could see the rust coming through the lap seam for the last few years.