Advice on repairing this rust hole pls

[ChasesDragons]

Hi all,
There was a paint blister on my old Volvo....poked it and a 4mm hole appeared!

It is about 15mm from the rubber windscreen just as an extra kick in the teeth.

I would like to repair it in situ, without taking the seal or screen out. Would a Tig welder be able to do it?

 

[AVI_8]

I would be surprised if under the seal there wasn’t a rusty patch, it’s a common rust area on old cars, you may be looking at the tip of the iceberg.

 

[tigdlo]

It won't be just a 4mm hole, I would take the screen out and do it properly or hit it with a ball pein hammer and fill it with fibreglass filled filler. IMO there is no benefit in doing a halfway job welding as it will trap moisture and rot out just the same as the filler job.

 

[ajlelectronics]

What you can see is the tip of the rustberg.

 

[jordhandson]

I would have a couple flat scrapers and flex the windscreen rubber up you will probably get another 25mm and see how far it goes the scrappers will also stop you damaging the rubber with the flappy, before going gun-hoe and removing the windscreen you may be lucky.

 

[Gareth J]

What's the outcome you want to achieve?

 

[JOEPRO]

Yes it's most likely going to open up into a larger area. The paint around the trim there looks a little odd. Like it's been fillered.

Pay a local windscreen company to come and remove that screen. Cheaper than breaking it.

Then clean back any areas of rust and you know when the screen goes back in nothing is festering behind it

 

[ChasesDragons]

Ah nuts! You are mentioning the fears that I dont want to face!

I have given it a good poke around, it is going into clean metal at the edges of the hole. It was a paint blister from water inclusion, possibly. If Tig or mig of the hole was not do-able without the screen off, I was thinking of temporarily using chemical metal like Jweld instead of fibreglass, hoping it wouldn't absorb water. I have cans and cans of Bilt-Hamber wax that I was going to spray into the cavity, but then welding in the future may be a hazard.

Gareth J - The outcome is to postpone the inevitable, frankly. I spent a lot of time and money getting this automotive monstrosity to running condition. I cannot go all-out and do a strip and rebuild, mentally, physically or financially - right now.

Warmest REgards to all!

 

[bricol]

Blob of some form of sealant, stop water getting in there and making something else rot.

Make a mental note to come back it as and when . . .

Windscreen in rubber seal are nice and easy to remove and refit, given a hint of patience and care, and if your first time, another pair of hands to assist - but you may well find other horrors in the bottom of the channel . . . maybe keep them until another day

 

[julianf]

If you were to Tig it in situ, you would end up with a boiling pool of metal oxides. The corrosion that is on the back of the part would boil up to the surface of your weld pool.

As to if this would be worse than it is - probably not, but it wouldn't be a nice repair.

 

[Dcal]

I'd be very supprised if that isn't a lot worse.
From the photo lt looks like it was repaired before and is coming back.
For a lasting repair the window needs to come out which should be pretty straight forward if it's toughened but trickier if it's laminated.

I'd bite the bullet and scrape the paint off to see what lies beneath.

Link to a similar repair I did.
It could be anything from a tiny blister to a horror show.
My front screen was many times worse however, I wouldn't expect a Volvo to be anywhere near as bad and I don't want to put you off.

25 year old Alfa 75 back from the brink (hopefully)

Hi @marlinspike what projects do you have on the go? Still got the Saab? Any chance of an update? It's a bit lonely on the car projects front here at the mo, could do with a bit more variety. Starting to put a few bits back on the car and discovering bits that need sorting as I go. I've...

www.mig-welding.co.uk

 

[arther dailey]

a well placed hubba bubba untill you have the time n monies to do it properly , thats presuming the rest of the shell/car is worth it

 

[Gareth J]

Ah nuts! You are mentioning the fears that I dont want to face!

I have given it a good poke around, it is going into clean metal at the edges of the hole. It was a paint blister from water inclusion, possibly. If Tig or mig of the hole was not do-able without the screen off, I was thinking of temporarily using chemical metal like Jweld instead of fibreglass, hoping it wouldn't absorb water. I have cans and cans of Bilt-Hamber wax that I was going to spray into the cavity, but then welding in the future may be a hazard.

Gareth J - The outcome is to postpone the inevitable, frankly. I spent a lot of time and money getting this automotive monstrosity to running condition. I cannot go all-out and do a strip and rebuild, mentally, physically or financially - right now.

Warmest REgards to all!

If you just want to keep the water out of the hole, make a patch from roof flashing and warm it on. The rust will be growing from the inside out, driven by leaks or condensation from the inside of the metal. Or leaks from behind the rubber.

If you think of a scutty roof flashing patch as "palliative care", that lets some other, more catastrophic failure happen to force your hand, it's easier to justify in your head!

 

[8ob]

For a temporary fix you could open it up with a step drill and fit a blanking grommet.

Bob

 

[steveo3002]

wait till you have time and screen out and bare metal that whole area , chances are theres similar in other areas along the windscreen lip , once its cleaned up and you can see whats going on post some more pics

id not be surprised if thats the size of a golf ball once cleaned up....although doesnt make alot of odds if you have to do all the same prep work anyway

 

[Bullet2012]

yep leave it alone it will be fine in the end

 

[ChasesDragons]

ok, thanks all, you can stop putting the boot in, now.

I will plug it until I find time and inclination. I will expect a sieve when I open it up, at least I won't be disappointed!

 

[CompoSimmonite]

Looking at the guttering end I wouldn't be surprised if you find filler in the area

 

[dave h 2]

One day you'll slam the door or jack it up and the screen will go skkeek right across (it's a bit like the sound ice makes when it cracks but more expensive)
Just say it doesn't have a vinyl roof that's just a tiny little bit bumpy.

 

[Chippie]

Hi all,
There was a paint blister on my old Volvo....poked it and a 4mm hole appeared!

Make the hole bigger….,,the 4mm hole will be gone….magic…