1990 ranger windshield rust

[John501]

My 1990 ranger has a windshield leak due to rust. I know it will need to be removed and new metal put in. I've thought about welding in the new metal but I'm concerned about future rust underneath the welds. Between the two layers of steel. I've read that some people use structural adhesive instead and glue in the new metal sheets. Anyone done this repair before, and any tips on whether I should weld or glue?

 

[Paul1991]

I'm a little late to reply to this, I've recently joined and have been scrolling. I have a similar issue on my 92 xlt, my rust being in the roof above the windshield pillar. I've used panel bond adhesive in the past on projects and still prefer good old welding. Clean the good metal that is left the best you can and top dress it with the rust preventitive of your choice. The hard thing with panel adhesive is that you need the adhesive, then a special application gun to use it. Something like a windshield area isn't a large area and the thickness of the adhesive could throw off the tolerance of where your windshield is going to sit even if clamped in tight. I panel bonded rockers onto my cousins Silverado once and was not happy as compared to welding, but that's the way he wanted it done. Also although paintable, everywhere that was painted the paint fell off quickly with good prep work (not that it would be an issue on a windshield area). Just some food for thought, you have to do what you think is best for your application.

 

[John501]

I'm a little late to reply to this, I've recently joined and have been scrolling. I have a similar issue on my 92 xlt, my rust being in the roof above the windshield pillar. I've used panel bond adhesive in the past on projects and still prefer good old welding. Clean the good metal that is left the best you can and top dress it with the rust preventitive of your choice. The hard thing with panel adhesive is that you need the adhesive, then a special application gun to use it. Something like a windshield area isn't a large area and the thickness of the adhesive could throw off the tolerance of where your windshield is going to sit even if clamped in tight. I panel bonded rockers onto my cousins Silverado once and was not happy as compared to welding, but that's the way he wanted it done. Also although paintable, everywhere that was painted the paint fell off quickly with good prep work (not that it would be an issue on a windshield area). Just some food for thought, you have to do what you think is best for your application.

I think I'll go with welding on it, I've been dragging my feet in the project holding out till it's warm again. I'm not a welder and my main concern was it rusting between the two pieces of layered metal. Since it has an upper and lower roof skin, and I'll need to cut and weld in a small bit of the upper lip, on the pinch weld where it's rusted. I've looked at some weld through primers that you paint the metal that's going to be layered to help prevent rust. I just want to do the job and not have to it do the same thing in 5 years because it rusted again.

 

[Paul1991]

If your not a welder, I'd say in the very least practice on a guage of steel close to or the same as what you'll be welding. Go to your local tractor supply or whatever you have in your area and get a cheap sheet of metal, cut some pieces and have at it. Do you have a welder?

 

[John501]

If your not a welder, I'd say in the very least practice on a guage of steel close to or the same as what you'll be welding. Go to your local tractor supply or whatever you have in your area and get a cheap sheet of metal, cut some pieces and have at it. Do you have a welder?

I don't have one currently, but I have a friend who is a farmer so he has a MiG welder. I do need to practice on sheet metal though.

 

[Paul1991]

Lol it's always the farmers who have tools to borrow (I grew up farming in a small farm town, so I'm familiar with that scenario). Honestly, get yourself a harbor freight 115v flux core welder. I have the titanium brand welder it's a little green one. It requires no gas with flux core and is awesome for anything under 1/4 inch. I've done a ton of cab corners and rockers with it. Floor pans as well as fixing mower decks and building exhaust systems. Great little unit if your getting into the welding hobby . I use mine with a generator for field repairs and stuff like that as well. It only weighs about 15 pounds or so.

 

[John501]

Lol it's always the farmers who have tools to borrow (I grew up farming in a small farm town, so I'm familiar with that scenario). Honestly, get yourself a harbor freight 115v flux core welder. I have the titanium brand welder it's a little green one. It requires no gas with flux core and is awesome for anything under 1/4 inch. I've done a ton of cab corners and rockers with it. Floor pans as well as fixing mower decks and building exhaust systems. Great little unit if your getting into the welding hobby . I use mine with a generator for field repairs and stuff like that as well. It only weighs about 15 pounds or so.

Yeah I was looking at getting one after the holidays they look like good units.

 

[Paul1991]

They are very good for what they are. Just don't expect to be doing frame work or building bumpers with it. Lots of good little uses to have one for

 

[Shran]

Get one that you can run gas with. Flux core wire makes fine welds but it's very dirty, spatters much more than solid wire with gas and is harder to learn. I used a shit ton of it years ago... Even a cheap 110v machine with gas can do excellent work and you will not regret it.

I would caution you that you have a significant project ahead of you. Repairing that area so that it's fixed and looks good and will last takes skill - it may be a good idea to at least find someone familiar with body work to give you some pointers.

 

[Paul1991]

Flux core can be ok for this kind of work as long as you do your work to keep stuff clean. Ultimately it's the same as using a stick welder just in mig form. As long as the machine is set up properly and you burn in your welds good you're fine. I've welded in countless wheel arch repair panels on projects with no problems that had no signs of problems years after body work and paint. Like anything else body related it's all in prep and taking time. If you have more money for something that takes gas go for it, but if it's going to sit on a shelf more than you use it then a flux is just fine. This is just my opinion. I've welded stick, mig with gas and mig with flux and it's really all in how you set the welder up.