Rust around the windshield- anyone ever repaired it?

[I_bRAD]

I've got some pretty serious rust at the top edge of my windshield- to the point where it leaks when it rains hard enough and leaves a pool in the floormats and shifter boot. As far as I can tell, the only way to fix it is to pull the windshield, weld in new steel and reinstall the windshield. Has anyone ever attempted this? I'm no bodyman so I'd be paying someone to do this- those of you who are bodymen, is this a big deal or not as tough a repair as I think it will be? I've got a lot into this truck, would be a shame to give up now that its running so well...

Thanks, bRAD

 

[T4R2014]

Cutting and welding will mean big money. They will have to remove interior panels and labor will add up. Paint is another big money procedure. If you like the truck enough and want to keep it, then by all means go for it.

 

[Gadgetguy]

Cutting and welding will mean big money. They will have to remove interior panels and labor will add up. Paint is another big money procedure. If you like the truck enough and want to keep it, then by all means go for it.

Agreed, I would be surprised if a shop charged you less than $3000 to do all that when all was said and done. After the windshield is out I bet everything under the glass and the trim is equally bad or even worse...

Sometimes it's just easier to buy a new one and count your losses, I've done that many times now.

 

[T4R2014]

Honestly though, go to a body shop and see what they say. If you really like this truck, then it may be worth it.

 

[xcmtb83]

Post pictures of said rust, even though the worst may not be visible.

I had this same thing happen to my Tacoma. A friend and I removed the windshield and sandblasted as much rust as we could then primed and painted it along with blending it into the roof. I attempted to get a few estimates from body shops but few wanted to mess with it because they couldn't tell just how bad it was.

Fast forward to present, the Tacoma repair is holding up just fine but I have noticed my 3rd gen has some light rust forming around the window seal. I am not leaking at this point but I still plan to fix it. This next time around I plan to remove my already cracked windshield and remove as much rust as I can and primer the area before I reinstall the windshield. I don't plan on doing any paint work because I plan to install slightly oversized trim/molding that should cover all currently affected areas.

 

[IBallEngineer]

I've got some pretty serious rust at the top edge of my windshield- to the point where it leaks when it rains hard enough and leaves a pool in the floormats and shifter boot. As far as I can tell, the only way to fix it is to pull the windshield, weld in new steel and reinstall the windshield. Has anyone ever attempted this? I'm no bodyman so I'd be paying someone to do this- those of you who are bodymen, is this a big deal or not as tough a repair as I think it will be? I've got a lot into this truck, would be a shame to give up now that its running so well...

Thanks, bRAD

Serious rust is a serious problems. But...
:worthless

Even looking at it in person won't tell the complete story. Until the windshield is out and you start digging out the scale, you can't know what it will take to repair.

I did a repair such as this on a 1st gen about 11 years ago, still going strong. Don't be afraid of it, but don't think it's going to be cheap either.

Now let's see some pictures, we are a visual group don't ya know...

 

[sportscarfan]

Mine has the same problem. Blame the last guy to replace the windshield who cut the paint removing the old one and not bothering to reseal or cover with anything...then proceeding to install some generic molding that isn't correct either. This is all according to a "good" installer I talked to last year about getting mine fixed.

I don't want to open up the can of worms I forsee the fix to be, so I applied a bandaid last November. With compressed air and toothbrushes, I spent an hour or so getting as much loose rust out from behind the ill-fitted molding and treating with rust converter. I let it all dry out and stuck a "bandaid" over it - a 1 foot wide strip of flat black vinyl that runs across the top of the windshield. Plenty of overlap on both the glass and roof to keep moisture out. The 4runner sits out 24-7 in the CO sun and the patch is still ok.

 

[I_bRAD]

I could remove the trim/interior myself to save some money.

Here are some pics, you can just make out the two worst spots in this photo:

One of the bad spots:

The other bad one (This is the one that actually leaks):

The rest isn't too far behind:

I agree that it doesn't look good! Problem is that I've redone just about everything on this truck except for the body so I really don't want to start from scratch again! I have a feeling a truck with a good body would cost me more than the repair and I wouldn't be back at square one on mechanical stuff. 4runners with good bodies don't really exist around these parts- mine IS one of the ones in "good" shape1

 

[IBallEngineer]

I could remove the trim/interior myself to save some money.







I agree that it doesn't look good! Problem is that I've redone just about everything on this truck except for the body so I really don't want to start from scratch again! I have a feeling a truck with a good body would cost me more than the repair and I wouldn't be back at square one on mechanical stuff. 4runners with good bodies don't really exist around these parts- mine IS one of the ones in "good" shape1

Although this is bad, its not terminal at all. Pull the windshield, scrape and grind, then grind, then scrape. Then weld in some patches, then grind and grind and grind. Once you have it pretty well cleaned up, you clean it up with a good metal cleaner, then seal it with a rust inhibitor.

THEN you can fill and sand and prime before paint. Piece of cake, cup of coffee, walk in the park.

:whoo:

 

[I_bRAD]

Piece of cake, cup of coffee, walk in the park.

:whoo:

Only slightly harder than an oil change!

 

[T4R2014]

Then weld in some patches

Not exactly a piece of cake if you don't weld... Unless OP can weld.

IMO, since you say you've re-done pretty much everything, I think it's worth it for you to fix.

 

[IBallEngineer]

Only slightly harder than an oil change!

EggZaaactly!!

 

[mtvp]

I've got some pretty serious rust at the top edge of my windshield- to the point where it leaks when it rains hard enough and leaves a pool in the floormats and shifter boot. As far as I can tell, the only way to fix it is to pull the windshield, weld in new steel and reinstall the windshield. Has anyone ever attempted this? I'm no bodyman so I'd be paying someone to do this- those of you who are bodymen, is this a big deal or not as tough a repair as I think it will be? I've got a lot into this truck, would be a shame to give up now that its running so well...

Thanks, bRAD

I had the same issues. A cracked windshield that needed to be replaced. The Auto 1 place that I went to discovered to the bad rust around the top. Sent it over to a body shop across the street.
Had it fixed by them painted and back to the windshield (Auto1) the next day.
Long story short I was out the door for $500.00 bucks for the repair and windshield.

 

[I_bRAD]

I had the same issues. A cracked windshield that needed to be replaced. The Auto 1 place that I went to discovered to the bad rust around the top. Sent it over to a body shop across the street.
Had it fixed by them painted and back to the windshield (Auto1) the next day.
Long story short I was out the door for $500.00 bucks for the repair and windshield.

That sounds encouraging. I'll have to get it in and see what kind of quote comes back. Did a quick search for 5sp 4X4 in Ontario last night and the results were looking pretty bleak. I think my body is still better than anything available right now and I can guarantee it's better mechanically!

 

[SpidermanGeek]

Mine was done at some point from the Previous Owner. He must have had to replace the windshield and it looks like whoever did it for him also cleaned up the rust and applied some sort of black sealer on the spots.

I don't seem to have any leaks coming from the windshield and although a little bit of rust is starting to show through the sealant, it looks like it's doing a good job of slowing down that process.

If I ever need to replace the windshield again, I'd make sure that the rust is taken care of again, but for now, it's pretty low on my list of priorities until it actually starts leaking.

To the OP, take these guys advice. Do whatever work you can on your own, then bring it to someone reputable who can remove the windshield for you, help you clean up/patch those troubled spots and reinstall the windshield with a new good quality (OEM if possible) molding.

 

[I_bRAD]

Unless OP can weld.

Never have, but that's never stopped me before! I'm taking it in for a quote tomorrow morning. Depending what they say I'm also considering a MIG welder and learning a new skill. Probably a useful skill to have since I tend to gravitate towards cars and trucks that are likely to have rust on them due to their age!

 

[T4R2014]

Probably a useful skill to have since I tend to gravitate towards cars and trucks that are likely to have rust on them due to their age!

I'm in the same boat. I just can't find many new(er) cars I genuinely like unless it's super expensive or sold overseas. I probably will need more land too because I'm starting to turn my backyard into what looks like a used car lot.

 

[I_bRAD]

So the first quote came in at 4100. To be fair, that was to do everything

roof, Fender, rockers, hood, doors etc. I'd essentially have a new body.

The cost of the repair is right at the value where I have to do some hard thinking. If I did that repair I'd have roughly 15000 into the truck, which is cheap compared to a new truck, but seems like a lot for a truck with 330000kms that's 18 years old! Granted pretty much the only thing that wouldn't be new at that point would be the engine and transmission, which seem to be holding up well...

 

[KidVermicious]

Depending what they say I'm also considering a MIG welder and learning a new skill.!

This.

Body shops get to charge a premium because people are either too lazy scared to buy a new tool and learn a new skill. It sounds like you're not the former, so go get yourself a new toy and start practicing. :cheers:

 

[T4R2014]

Body shops get to charge a premium because people are either too lazy scared to buy a new tool and learn a new skill. It sounds like you're not the former, so go get yourself a new toy and start practicing. :cheers:

Not necessarily. I barely have time to do an oil change, let alone do body work that will look nice.

OP, try making some friends that do body work.