Windshield frame rust

So... When I bought my '68, I knew I had a road of metal work ahead of me, in addition to a few other odds and ends. Today, while I was removing the visors and rearview mirror to work a pattern for an overhead dash, I discovered that the strip of sheet metal that they all screw into running across the inside top of the windshield was rotted to the core. My drill slipped off the screw of one visor and actually popped right through the sheet metal. When I knocked across the entire strip, it all sounded like wafer paper. I'm almost pretty certain that the lip that holds the windshield gasket in place is crumbled rust dust from the drivers side bar all the way to the center of the windshield.

Now, I've seen some sheet metal work done on rusted out window frames on some of the first gens, either here or on the VCVC website, to the point that the frame is as good as new.

My question is, how much am I looking at to fix the problem?

I paid $900 for the thing swearing I was going to bring back the custom van craze, as a 33 year old youngin.

Everyone here always gives me outstanding advice that I greatly appreciate. I hope the fix won't cost more than I paid for it, but I pretty much know it probably will be.

Thanks in advance.

Good luck. The guys at the body shop took the windshield off mine today and found the same situation. Crumbling all the way around. They are going to have to rebuild it somehow. I'll take pics.

Please do. As for mine, the inside of the top frame is rusted, but the outside skin is good to go. Someone else pointed out that it was just sheet metal that was tucked back, and sent me a photo of where he just cut out that strip of metal the visors screw into. However, I notice that the lip the gasket sticks to is rotted pretty decent, at least from the drivers side bar to the just behind the rear view mirror. It has to do with a hole in the roof from the previous owner. I think he may have had a super scoop, pulled it off and then sealed a piece of sheet metal over the hole using window glaze. I ran a thick bead of RVT over the seam to suffice until I can get a new roof skin to cover the entire cab section, as the roof is pretty dented and creased there.

Wow. I can see how that could cause some serious moisture problems. I'll get step by step pics of mine being repaired. Not sure when they will tackle it though. Fairly soon though since it has to be complete by February.

Good deal. Thank you kindly. I may end up just searching for a 67-70 108 in better condition, once the VA completes my claim. Then I'll just list my '68 for the $900 that I bought it for. Hopefully, I'll be able to recoup my initial, hopefully.

Did mine myself :-)













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Nice job!

That looks great. I'm imagining that my top lip will look like yours once I take the windshield out.

Here are a few pics of mine in progress. He has cut and bent new metal and welded them in front of and behind the original metal. Then he will weld /fill the small holes then fill the pinholes with fiberglass.  Coming along nicely. Ever finish yours?

Not yet. Just maintaining until the VA finishes processing my disability claim. I'm up in the air as to if I will fix the frame, or sell the van and look for another 68 that is tip-top.

Gotcha. Good luck!