Rust repair around windsheild

Well my windshield started to leak. Kept finding water on the carpet after a rain shower. Well, after having my windshield replace about 4 times, I started to notice rust around the gasket. I guess safelite didn't prime the area after removing all the broken glass. The guy who installed the new one after it fixed the rust said they were notorious for that practice. So, I decoded to fix it myself since none of the local shops would touch it.

Tools needed:

Windshield removal tool
Rust removal tools, What ever you want. I used to following:
Drill with various attachments.
Angle grinder with wire wheel
Dremel with various attachments
Various sand paper grits
Body filler
POR-15 Rust Preventive Paint
touch up paint

I tried to remove the least amount of body part possible. Don't do it, remove them so you don't damage them.

What I needed to remove:
Hood
Cowl
Fenders

http://img.photobucket.com/albums/v448/therealsundance/s-10truck006.jpg
http://img.photobucket.com/albums/v448/therealsundance/s-10truck007.jpg


I started by chipping all loose paint off. Next, I got down to business with the power tools and removed all the rust.

I forgot to get pictures before I started and at this point.


The surface was pretty pitted so I opted to go with the POR-15 with metal filler. I put plenty of coats on to fill in all the pitting.


Now, I had only one small spot on the drives side pillar which I filled in with putty.
http://img.photobucket.com/albums/v448/therealsundance/s-10truck012.jpg




The other hole I had in the top area where the windshield caulk would be placed was filled in with the POR15. I should have used lead or body solder. But, I was unaware of that method at the time.

http://img.photobucket.com/albums/v448/therealsundance/s-10truck011.jpg





After POR15 was applied

http://img.photobucket.com/albums/v448/therealsundance/s-10truck003.jpg

im glad someone else has done this... i will be on this venture this up comming spring for my prelude..
My rust is a whole lot worse.... ill post som pics to show what im talking bout...im will be working with body solder method... ill keep good pics to show some steps....

the window pillar on my 93 has rusted so bad it cracked the windshield on the drivers side:banghead: