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Originally Posted by 67_SS396
Over the years, I've had great luck using Rust Bullet. It's not as tempermental as Por15. I have a 48 Farmall that my grandpa bought new that I'm restoring very slowly. I treated the rusty battery box over five years ago and haven't painted yet. The rust still hasn't come back. I coated the floor pans of a 67 Camaro that I did some work on and they haven't shown any rust growth. That was seven years ago.
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Thanks for the tip! Unfortunately, after the discovery I made today, I think I'm going to avoid the POR-15/Rust Bullet/Rust Encapsulator route, and go more for the sheet metal replacement.
Ruh, roh!
Got the windshield out this morning (in one piece, no less!) and made another unpleasant discovery... more rust! It was definitely worse than I expected based on the small bits of rust on the outside of the seal, but it's manageable.
I've been re-thinking the POR-15 plan. This windshield area is beyond POR-15'ing, and if I'm going to go through the effort to patch this up, I will probably just patch everything else too. That also means I'm going to be removing the blower box area panel from the cab. It won't be fun, but I really want this to last a long time, and POR-15 seems kind of like a bandaid. It might last 5 years, maybe 10 years. But I want this to last at least another 25 years! Whether that's foolish thinking, I don't know, but it's what I'm striving for. I just know having POR-15 covering up rust will bother me in the long run, because, well...there is still rust.
Here is the majority of the rust (passenger side). I think this is also definitely the source of the floor rust as well, as I can see the trail from up there down the firewall and to the floor. I've got a photo of that too.
Driver's side is better:
Gently cleaned some of the scale and loose rust off of the other side with a toothbrush:
Here, you can see the water trail from the windshield down the firewall:
