Hi experts/all! I have decided to take on the 'rot' in my lower windshield area on my l/m coupe. I've looked at some other posts (especially those with pics), but I'm still scratching my head some. I am DEFINITELY not a "body man"....but I can follow instructions well with limitations. I don't weld and don't have metal working tools.(bend/stretch/etc).
I bought the 'repair panel' from a club member (he purchased from Clarks)....the problem is....the worst rust is in the 'corners' of the lower windshield. there is very little rust in the area that the patch panel covers.
Did others that do this repair experience the same issue? or is my car just rusted in this unusual spots??
See pics for what I am referring to.
thanks!!
p.s....I have a friend that is supposed to do the welding for me, but again, welding in the patch panel won't repair the worst areas.

George O¸
1967 Corvair 500 110/PG. in family since 1969 with 1200 miles(75k currently).
,,

Hmm, it does look problematic. How are you planning to attach the panel without welding? If you really want to fix it (I’m not sure it’s a good idea; how is the rest of the car?) the first step is to wire wheel and grind away all the loose material from prior failed repairs and any factory lead left in the seams.

Ken Henry, Rochester, NY USA
1965 Corvair Corsa
140 hp, 4 speed

Phil....thanks for the cheerleading...I NEED it.

Ken, the rest of the car is very good...AND it is sentimental...My dad (Big George) loved the car...and its about all I have left of him (RIP)....so the car WILL live on. (I've rebuilt the drivetrain and it drives like a dream!)

I have a friend that is an 'expert painter/body man'....he is going to "coach me", but I've sent him pics and he's a little perplexed too. (he's supposed to come over tomorrow to look it over, but I was hoping to get a little Corvair expertise to share with him first.)

I'm wondering if this is what others have found as I know the lower windshield rot is "common" in late models. I just expected it to be in the area of the patch panel. I was surprised that the patch panel area was pretty solid, but the corners are what's rotted.

George O¸
1967 Corvair 500 110/PG. in family since 1969 with 1200 miles(75k currently).
,,

Time to buy a crumpled donor body and cut out what you need.

MODERATOR
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...............110-PG.................................................Webered-Turbo

Certainly not the recommended way to go, but you could use resin and fiberglass cloth. Did many this way back in the day. If done carefully, the repair can last a long time and look fine. I know I'm going to get blasted for this suggestion, but, it works. Also, if memory serves, there were drain holes in those corners.

Frankford, De., eight miles north of Ocean City, Md.
1966 Corsa convt.

Looking back at the work I did, I extended the patch into the fender slightly on the driver side. I think corrosion tends to spread under the lead in that area. No need for a parts car, most will have some damage in there and sheet metal cut to shape will work. I also found that I had to make some relief cuts in the Clark’s panel to fit the body contour and windshield properly. This album will show you some of the common areas rust can lurk! Good luck!!

[flic.kr]

Ken Henry, Rochester, NY USA
1965 Corvair Corsa
140 hp, 4 speed

Thanks guys....I appreciate the advice/direction.

Ken...wow! I wish I had your skills I remember seeing some of your pics from a previous post. That car must have also had some special meaning to deserve all that work you put into it!!

I'll see how my buddy decides to approach and will try to provide updates. I hated taking the car 'down' during this time of the year, but it needs to be done. I think the authorities would frown on me wearing my goggles without a windshield, but I'd rather be driving it right now!

Thanks all !!

George O¸
1967 Corvair 500 110/PG. in family since 1969 with 1200 miles(75k currently).
,,

Hi George, no, just a random purchase that looked "OK" and was hiding 10x more work than I anticipated. Fortunately I enjoy working on it and can afford to keep up with costs at the fairly slow rate of progress I've been making! Good luck and keep us posted on progress. It may not be too bad after wire wheeling out all of the loose material. Be sure to a wear a good mask as lead is used in that area... Ken

Ken Henry, Rochester, NY USA
1965 Corvair Corsa
140 hp, 4 speed

Clark's panel relieved to fit opening (note welded up areas along the lip over the dashboard) and installed. I used a waterproof filler over the welds (USC All-Metal) and lightweight filler over that.

SAM_1460 by kenhenry_06268, on Flickr

SAM_1459 by kenhenry_06268, on Flickr

Ken Henry, Rochester, NY USA
1965 Corvair Corsa
140 hp, 4 speed

Not to criticize Ken, but when you weld in that panel, try to replicate the factory spot welds closer to the bottom of the channel, as this panel ties in the top of the trough and the toe panel to the fender tops and the windshield frame. This panel helps decrease body flex when welded in at the factory attachment points. Big George - if the middle is good, leave it be and just fix the corners. Don’t let someone convince you to do the whole panel if not needed. I had that happen, and while the bodyman was well intentioned, the retro panel didn’t fit as well as the factory. I did the next one myself.

Mike
YS-117

Mine is plug welded to the underlying body panel lip. Those little tacks are just anchoring it to the flimsy dash.

Ken Henry, Rochester, NY USA
1965 Corvair Corsa
140 hp, 4 speed

Thanks Ken and Mike,
Good advice and I appreciate it.

Ken....I actually used those very pictures you just posted to show the guy I'm hoping that does the work as an example of what I needed/wanted done. Very helpful.

Mike...I'm actually "little George"....my dad was the real 'Big George'....it was a long running joke in my family. When I was growing into a man and my voice got deeper, when someone would call the phone and my dad would answer, he would always ask "do you want Big George or Little George?" and that stuck as my friends would give me grief about it. So my 'handle' on here "BigGeorgesVair" is a tribute to him!
Thanks...."Little George"

George O¸
1967 Corvair 500 110/PG. in family since 1969 with 1200 miles(75k currently).
,,

Sounds good, Little George. Glad you are keeping Big George’s ride in good shape!

Mike
YS-117

BigGeorgesVair Wrote:
-------------------------------------------------------
> Thanks Ken and Mike,
> Good advice and I appreciate it.
>
>.
>
> Mike...I'm actually "little George"....my dad was the real 'Big George'....it was a long running joke in my family. When I was growing into a man and my voice got deeper, when someone would call the phone and my dad would answer, he would always ask "do you want Big George or Little George?" and that stuck as my friends would give me grief about it. So my 'handle' on here "BigGeorgesVair" is a tribute to him!
> Thanks...."Little George"


Way Cool, back when CB radios were popular, my handle was Big Brother, and my younger brother , now passed, was Little Brother.

J.O.

65 Corsa Turbo Vert
79 Honda XL 500S
69 Honda CL 160 D
2010 BMW F 650 GS
2003 Bounder 36D
2013 KIA Optima SX turbo-AKA ZIPPY (wife,s car)
69 Newport Holiday Sailboat
Baja 150 dune buggy cart
Coleman HS 500 UTV
2016 KIA Sorento SXL Turbo

Bethlehem,Pa

Well...My friend stopped by earlier to check out the damage. He took at it a little more 'aggressively' than me. I guess it will have to look WORSE before it looks better. We have a plan. So I'll try to update as it progresses. (which I expect will be slow)
I'm going to get to grinding and he's going to start fabricating some metal patches for the corners and sides that are rotted.
Here's some updated pics from after him hammering and chipping away at it.

Thanks....George

George O¸
1967 Corvair 500 110/PG. in family since 1969 with 1200 miles(75k currently).
,,

Just dive in and do it...

kenzen
66 Monza Coupe 110/PG
Bel Air, MD

Thanks Kenzen...these pictures help. I guess that's what I'm doing...I can't wait until mine looks like your 2nd picture (I hope in the not too distant future!)

George O¸
1967 Corvair 500 110/PG. in family since 1969 with 1200 miles(75k currently).
,,