Glass pinchweld

[Mike_The_Grad]

Hey everyone, I recently tackled the rust issue I had around the rear window glass pinchweld and gasket area on my 72 c10. I had to cut out all the rusted areas and fabricate my own patch pieces. It wasnt fun and took me an entire weekend to get it all welded in. Im happy with how the areas I patched will look when the glass and gasket are installed. But my question is, how important is it that the pinchweld area itself is smooth and flat where the gasket is installed around the back glass frame? I ask because it was proving rather complex to find patch pieces that marched the offset lip of the pinchweld area around rhe back glass. So I tried to simplify the work by only cutting out the area that was rusted and leaving the factory spot weld pinchweld intact and using sheetmetal with a 90° press bend to fill in the missing pieces. Ill include some pictures for clarity. Because my welds in this area are not completely super flat. Im worried about having leaks when I reinstall the glass and new gasket. I've already got a ton of time invested in the repair and seriously trying to get to the next step in sanding and epoxy priming the outside cab so I can apply my 2 part drip rail sealant and get the cab fully sealed before the rainy season starts here in Southern ca. I dont have a covered area to store the truck while I work on it. And these short winter days are killing my work time with usable daylight hours. Thanks for any input.

And yes I see the pinholes I need to go back and weld up. Im only asking about the area the gasket is supposed to seal against for the back glass window.

[raggedjim]

I've been struggling with the same area (well, really the whole rear cab) and I feel like if you can get the window gasket to sit flat then you will be fine.

You said you're happy with the way the window/ gasket fit so I'm assuming you have tried them? Do you know how much the window gasket overlaps the rear cab panel?

[Mike_The_Grad]

On my truck the gasket overlapped 1/2"-3/4" roughly. That gasket was at least 20 years old since thats how long I've had the truck for. And may well be the original gasket. It came apart like it was the original. I picked up a precision replacement parts gasket and checked the fitment on the window frame. Seems to be pretty close to what was on there before. Im just unsure where the gasket actually seals. If its the spot welded punchweld area or the stepped lip of rhe window frame. Either way I got to weld up my pinholes.

[Steeveedee]

Anyone here work with auto glass who can give him some pointers?

[Mike_The_Grad]

Thanks Steven. I went ahead and pulled out the welder today. And of course some of those pinholes blew out into holes about the size of a pencil. My welding gas tank is running on fumes right now. Personally, im done with this rust repair. I hate it. I want it to be over with already. I want to get to the fun cool stuff like putting my new carpet kit in, putting my valve covers I just got back from the chrome shop, new carburetor, drop leaf springs, hydroboost conversion, new front brake components, new grille and bumper. You know the cool stuff. Ha ha

[raggedjim]

Originally Posted by Mike_The_Grad

Personally, im done with this rust repair. I hate it. I want it to be over with already. I want to get to the fun cool stuff like putting my new carpet kit in, putting my valve covers I just got back from the chrome shop, new carburetor, drop leaf springs, hydroboost conversion, new front brake components, new grille and bumper. You know the cool stuff. Ha ha

I feel ya, this is the part that weeds out the weak (I was real close to getting weeded)... Keep at it!

[Roostre]

Originally Posted by Mike_The_Grad

Thanks Steven. I went ahead and pulled out the welder today. And of course some of those pinholes blew out into holes about the size of a pencil. My welding gas tank is running on fumes right now. Personally, im done with this rust repair. I hate it. I want it to be over with already. I want to get to the fun cool stuff like putting my new carpet kit in, putting my valve covers I just got back from the chrome shop, new carburetor, drop leaf springs, hydroboost conversion, new front brake components, new grille and bumper. You know the cool stuff. Ha ha

Rust repair sucks, and I inevitably blow through the thin metal like you describe. Keep at it, it's discouraging while in it but feels like you have something accomplished when you're done.