Rust: Grind, seal and repaint.....or weld in a replacement part?

[Jeff V.]

Here's the short, short version.

I'm doing a rebuild on this Spyder. While pulling the windshield trim ahead of a windshield replacement, I noticed a lot of rust in the channel that holds the weather strip.

ASC installs a metal 'cap' over the stub of the original coupe roof. That's the part laying on the windshield in the first pic. The gray wavy stuff is the glue they used to hold it in place.

http://www.xtreme3s.net/spyder/pics/Header_rot5.jpg

This is the rusty remnant of the coupe roof.

http://www.xtreme3s.net/spyder/pics/Header_rot6.jpg

It gets progressively worse going over to the passenger side.

So...do I grind it down as clean as I can and hit it with some rust converter? Or do I cut out the spot welds and replace it with a section from a coupe parts car?

Another pertinent fact. There's rust underneath this part where the bottom side of the Spyder-specific header bracket was installed. It's the part that holds the latches and latch motor, as well as the sun visors. Removing the outer skin would let me get at that.

[DrGonzo]

Yeah that rust is pretty deep. Not much metal would be left behind after grinding all the rust away.

Are there any holes in the rust that would have allowed water to seep in between the skins?

I would start with grinding but if there are any holes or if you have to concentrate to long on one spot to remove the rust I would replace it. Just be sure the rust converter gets into the pits and it it sealed well.

[Jimvr4]

Jeff, if it was mine I would be very tempted to find a donor Spyder and get the entire windshield section. Didn't Mitoska have a salvage Spyder in his yard?

[mcshooter]

summit racing has the part that the windshield sets on for camaros and pontiacs. i just welded one in for a 1970 pontiac that looks like you might be able to rework to fit. you might go to a local sheetmetal shop in your area and they could duplicate that part. take it with you , we had a guy here named the tin man who used to do this for folks but is now retired.. he could make any metal part anyone needed and any sheetmetal guy should be able to do this

[Jeff V.]

I didn't think Mitoska had the front part of the car any more. But I'll check.

I can replace this skin piece with one from a coupe. I just need to find a donor car.

I agree that it'd be nice to have the entire header assembly to clean up and re-work though.

[Jeff V.]

I leveled out the good metal with my angry grinder. The damage is pretty deep.

http://www.xtreme3s.net/spyder/pics/Header_rot7.jpg

[Chris@Rvengeperformance]

I don't know Jeff, I would consider getting a professionals' opinion. I know you want to fix it right, but I'd be scared to cut much metal out of a spyder.

[Jeff V.]

It's just an outer skin piece. A dozen spot welds and a handful of stitch welds.

We watch people graft on whole front clips. Hans just replaced half of a rear quarter panel on a badly smashed VR4. This should be cake.

[Ange]

nvm wrong post

[Toni]

Hey Jeff,

I still have my hardtop roof that I removed. Need any pictures/info on it to compare what you have? Might give you an idea if you can use a coupe roof to fix the rest.

[Jeff V.]

Not just yet, but I might take you up on it. Thanks.

Right now I'm working on getting a roof segment from a junkyard coupe. If it works out, it should only cost ~$25.

[Toni]

How the progress?

[Jeff V.]

You could say things are going well.

Old n rusted
http://www.xtreme3s.net/spyder/pics/Header_open4.jpg

New hotness
http://www.xtreme3s.net/spyder/pics/Header_repair1.jpg

Got a piece of a donor Stealth....
http://www.xtreme3s.net/spyder/pics/Donor_header.jpg

Fashioned a replacement...
http://www.xtreme3s.net/spyder/pics/Header_rot11.jpg

Did some welding, painting, sealing and riveting...
http://www.xtreme3s.net/spyder/pics/Header_repair3.jpg

Which culminated with this today :D
http://www.bawcforums.org/VR/3kgts/SpyderGlass3.jpg

http://www.bawcforums.org/VR/3kgts/SpyderGlass2.jpg

I still have to paint and reinstall the garnish that covers up the top of the header, but that's easy work compared to everything else I've done. I have to reinstall a crapload of seals and trim pieces too.

[green-lantern]

Looks great Jeff, have you guys decided on a color yet?

[Jimvr4]

Looks great Jeff, have you guys decided on a color yet?

I'm thinking he's waiting a little bit. I think he just installed both windshield and rear glass. It would make sense for those to stay of the car if it were being painted.

[green-lantern]

I'm thinking he's waiting a little bit. I think he just installed both windshield and rear glass. It would make sense for those to stay of the car if it were being painted.

IDK, that car needs it pretty bad.

[Toni]

Nice! looking good. Awesome to save a spyder.

[Jeff V.]

We've got a couple colors in mind, but it won't be done any time soon. We need to just drive it for a while to see if we want to keep it. I don't care if it's ugly. At least it's got an interesting reason for being that way.

One of the colors we have in mind could actually make it harder to sell than if we left it as a 'blank canvas' :suspect: