Rust around the windshield- options?

[I_bRAD]

So- I've got some rust around the windshield and it's reached the point where the windshield is leaking (no, it's not the sunroof drains). What are some realistic options?

I plan to keep the truck long term, but I'm not a millionaire and I also am not terribly concerned about aesthetics. I don't have the skills to remove the windshield and repair it properly.

That said, here are two options I am considering. Anyone got any additions to that or other ideas?

Option 1- pay someone to remove the windshield, fix the rust and re-install the windshield. I would assume to do it properly you'd need to weld some metal in there. A difficult job, but also easy to "fake" and I'd have no way of knowing how good a job they did other than to wait and see how it holds up long term.

Option 2- pull the trim. Coat with POR-15. Fill groove in with silicone. Profit.
Does anyone think that will hold up, or am I just delaying the inevitable?

Thanks for any suggestions!

 

[PitbullRescuer]

Pictures would help greatly with giving you input on this.

But I'd suggest pulling the wind shield, sanding back the rust, using some Rust Converter, fill with new metal if necessary and then prime, paint, re-install the windshield.

 

[I_bRAD]

I'll get some pictures after work. Have you taken the windshield out before? How much of a pain in the ass is it? I suppose I could pull the windsheild and clean it up- and then just pay someone to weld in metal and reinstall the windshield myself. I guess that way I could ensure they don't just fill it up with Bondo and tell me they welded in steel.

 

[xcmtb83]

If you have never removed a windshield before there is a good chance you will break it. I had the same problem with my Taco. A buddy of mine sandblasted the rust, painted and then threw in a new windshield.

 

[99 sr5 highlander]

Another option is to kill all the rust and fill the holes with dura glass. It's basically like bondo reinforced with fiberglass fibers. I am in no way saying this would be better than welding new metal in, (and that's probably what I would do) but it would be cheaper and much more long term than silicone.