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Windscreen scuttle corner repair thread.

samba-lee

Well-known member
Joined
19 Aug 2008
Messages
1,050
OCD'ers beware - this is advanced warning not to read on!

As promised this is the start of my windscreen scuttle repair thread. It all started last week when I had something hit the windscreen resulting in a crack.

National windscreens are doing the screen fitting via Insurance and came round this morning to remove the old glass.

I was aware of rust in the corners and expected more besides. Here's what I found.

First picture, showing relatively nice looking scuttle panel, outer seal removed.

Second and third pictures: screen removed showing the extent of the rust as expected.

Forth picture is the problem as you can see where the glue was missed or there was a bubble or open cavity in the glue it has rusted. There was several of these along the bottom edge. So sorry guys this is clearly a factory install issue and it goes unseen until you remove the screen.

Now next post will be the rust removal and welding! :eek: I had to do so I shall keep you in suspense until then...
 

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Scary :eek:


Good luck.
 
Yikes! It ain't pretty is it.

Mine's been done before, but I would like a new screen due to some annoying small chips. I'm hoping the job that was done was a good one, and that there are no nasties hiding underneath. I do think that is perhaps a little over optimistic.
 
Drivers side, looks pretty bad eh? well after some angle grinder wire bushing and then careful use of a grinding disc there isn't much rust left, but there was a small hole about 5mm diameter just on the turn up the A-pillar. I gave the rest of the area a real good poke with a scribe and nowhere went through.

Welded a tiny patch into the hole and ground it down.

Used some BiltHamber Deox magic rust stuff which is just water based and have left it in the corner and will remove it over night. You can see this stuff visible eating the rust away.
 

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Can you get to the other side of the panel to put rust prevention in place?
 
dommorton said:
Can you get to the other side of the panel to put rust prevention in place?

Yep, it's not visible but I had my finger on the back of the little hole that needed welding so getting the waxoyl nozzle up there will be no problem and there was no apparent rust at all on the backside of the panel - it was nice and smooth (apart from there the hole was).

The panel repair will easily last another 15 years.

I'll first be painting it with BRUNOX epoxy anti rust primer then sneak in a very localised paint repair which despite the amount of rust will be almost invisible when the out trim seal it fitted.

Lee
 
Ah good stuff :thumb:
 
Passenger side.

Picture 1: Urgh.

Picture 2: a quick scrape and it looks a bit better.

Picture 3: Angle grinder + wire brush and a good poke revealed a couple of small holes (3/4 mm)

Picture 4: Cut the holes out to thicker metal

Picture 5: Patch welded in and ground back. Job done.

Windscreen scuttle rust removed diy. Cost: £very little.

Next, final wire brush after I remove the Deox then Epoxy anti rust.
 

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:eek:

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Get thee behind me Satan! Good grief Lee you have been in the wars with the tin worm in your 993, cracking job though!
 
Brilliant thread Lee ,
No doubt that all untreated 993s look like this under the screen , it just NEEDS to be done :frustrated:

Well done on doing all the work yourself , and good news that the underside of the frame isn't affected.

Have you thought about sealing/waxing between the screen and the scuttle once the screen is back in?
 
The rust along the middle section cleaned up easily.

I tell you unless a 993 has had this job done then I guarantee there will be rust.

The windscreen guy removed the old screen without much trouble and didn't break it, so it's almost worth removing it to investigate.

Given what I know now:

1) where ever windscreen glue has been applied properly there are no issues.

2) filling the groove with either windscreen glue or sealant as we have all discussed would prevent this, but would need to be inspected to ensure it is still well bonded. Any dirt in the groove would render the sealant useless. also not sure how it would bond onto the ptfe tape. :?:

Lee
 
What about filling the crevace with wurth anti rust or similar..
This stuff hardens to a candle like wax consistency ,would keep pooling of water at bay and would fight any rust if it appeared underneath.
 
ballcock said:
What about filling the crevace with wurth anti rust or similar..
This stuff hardens to a candle like wax consistency ,would keep pooling of water at bay and would fight any rust if it appeared underneath.

Maybe, although it the screen moves a little, the Wurth would probably not. I think a flexible sealant as Porsche recommended or even windscreen glue which is pretty much the same thing.

Lee
 
Top work Lee :thumb:
 

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