Sarge's rattle-can rebuild

[68Timber]

Originally Posted by Front Range

What'd you use to make such a precise cut - dremel?

I used a 4" cut-off wheel on the cuts that follow the windshield channel, but it's too big to go across it due to the depth there. To connect the long cuts I used this bit in my die grinder. I forget what those bits are called, but they move a lot of metal, a bud gave me a handful of them a few years ago. I used the tip of this bit, low rpms, slow and steady.

[68Timber]

Finishing up this repair, after welding in some patches and grinding the welds smooth I wiped some bondo over both spots to help smooth out the repair. Also, I had two other spots where the metal was solid but rust pitted. There wasn't any point cutting them out but I did want to stop the rust and repair the area best I could, so I treated them with rust converter and let them cure then wiped over them with bondo as well. Then the entire glass channel got sanded, primed, and painted.

[68Timber]

Real, real happy with the way this turned out. Whoever said I'd rather be lucky than good said a mouthful. The new windshield should be installed today.