edited windshield rust repair 5 28 11 (PDF)

PLEASE NOTE: THESE REPAIRS WERE COMPLETED IN MAY OF 2011 OVER A LONG HOLIDAY WEEKEND.
AS OF EARLY 2015 THE RUST STARTED TO COMEBACK. SO I GUESS IT SERVED ITS PURPOSE AND DELAYED THE INEVITABLE.
AT THE TIME THIS CAR WAS A DAILY DRIVER THESE TECHNIQUES WERE USED OUT OF DESPERATION TO SAVE MY CAR.
CURRENTLY I HAVE AN AIR COMPRESSOR AND WELDER AND THE CAR IS UNDERGOING REPAIRS.
RUSTED METAL SHOULD ALWAYS BE CUT OUT AND REPLACED WHENEVER POSSIBLE.

tennhogfan
Senior Member

Join Date: Feb 2008
Location: Memphis Tenn
Posts: 520
280zx windshield area rust repair part1 (lots of pics)

1

In a perfect world, my DD would be a pick-up truck and my z would be a weekend toy only to
come out in fair weather. In reality, my z is my DD and although extensive repairs are more
difficult, anything is possible with adequate planning. I'm currently enjoying a 6 day hiatus
without having to drive the z, so I decided to tackle one of the notorious rust problems to
280zxes currently referred to as "the windshield area".

2

I'm dying to start on my JY turbo engine, but quickly realized if I don't take control of this rust
issue I won't have a car to swap a motor into.

3

So last month I stripped the interior (bagging and labeling accordingly) to not only assess
damage but to confirm a no-leak status after repairs have been made.

4

5

After going back and forth as to save or replace, I decided on a new windshield. I had planned
on buying the tools and urethane myself (I hate paying anyone to work on my stuff, esp. the z),
but as others have pointed out having a pro do it was definately in order. He's charging me $167
+ tax, not bad.

6

Not as bad as I thought, I was expecting large golf ball size rust holes. Some pinholes and one
pea-size area over the driver's side.

7

8

My wife said "why did you take the fenders off?" I knew what had to be lurking underneath.

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