The windshield is painted and drying. Lots and lots of work on it. 22 holes got welded up from hard top installs. 24 holes if you include the oversize hole and the one drilled next to it. On the bottom side for the base gasket to cowl seal. I run cross hairs and weld it back up. Then retrace the cross hairs and center punch it for a new correct size hole. There was also a bad rust patch from water sitting there.
Terrible rust and the only real bad spot. I welded every bit of this back. I also ruined a whole tungsten rod from blow back. I hate this type of repair. Grind your tungsten and instantly ruin it.
So the great big plug welds on the windshield frame cause leaks. The big lumps hold the lower gasket off the windshield frame and allow water to get in on the sides of the welds. I decided to grind and sand all of them off and give a flat surface for the gasket to seal against. This is my attempt to stop lower cowl gasket water leaks. Ok everybody can stop laughing now. I will try.
See the welds and gasket lines?
All gone.
A skim coat of putty for a super flat seal surface.
I coated the inside of every cavity with some left over internal frame paint.
Primered and some seam seal where it was needed.
It is done. Now to let it dry for a few days then comes reassembly. I hope the glass goes well. It had better. This glass is thicker than what you can get now. No coffee that day.
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