Auto body repair & detailing: rust around rear windshield, rear windshield, structural adhesive


Question
My wife and I are restoring a 1970 cutlass rallye 350. There are several areas around the rear windshield that have rusted through and some around the front. What is the best way to fill these areas and can it be done without welding?

Answer
I would sandblast the pencil sized area, and slightly recess the area with a ball peen hammer. Use the structural adhesive as a filler, then skim coat with icing. lead would do a wonderful repair here, also. I had the same problems with the roof on my 66 gto. It had a vinyl top, and it really made a rusty mess everywhere. The important thing is to get some parafin based undercoat sprayed on the back side of the repaired areas. Bill