The paint is just starting to bubble and turn a rusty color. Whats the best way to attack this without having to weld in a new piece of metal?

 

I attacked mine with a flathead and steel wool. than put on some rustoleum stuff on it. its just an inhibitor. should slow it down. dries black tho.

 

best way is to cut it out and replace.if u cant do that try some por15

 

So basically scrape that area down to the metal, then treat with some POR15 and respray bomb with a rattle can/clear?

That's prob the cheapest/easiest way I want to do this.

How bad does it look right now?

 

your rust? its better to hit it now. the longer you wait the worse it gets. id make sure your weather strip pulled out of the way to make sure there is none under it.

 

Good idea all around but I hate to say, almost always when its bubbled like that youre going to have to cut metal away to get rid of it all. Surface rust is one thing, but bubbled up "paint" (metal under the paint) is almost always a tell-tale sign of serious rust. Only way to know is to go at it. Get rid of as much as possible and if you cant cut it out at least get rid of all the loose stuff, hope it hasnt ruined the structural integrity of the metal, and POR the hell out of it. Good luck!

 

I used a wire brush to get the rust and paint away, then some 300 sand paper on an orbital, then hit it with some rust inhibitor stuff. before i started my paint job.

 

hey! that looks like mine! Seriously though fix it soon. Mine has gotten so bad that it literally rains inside my jeep when it rains. The only way to stop it is to cut it out, just like cancer. Converters and paint will not fix the problem - trust me I found out the hard way.

 

That is "inside out" the metal is already gone, by the time you get to solid steel you will have one large hole.

 

So this is bad huh. Must be a PITA to replace the metal there. Oh well, I will scrape away and see what I am working with.

 

take some pictures and post them when you do it so I know what I'm in for lol.

 

s*** I forgot to mention sand paper! use that for the simple fix. but yeah cutting out is the best way.

 

Rust like that will be twice as big as you expect...

 

Use a grinder if you have one, and repair with fiberglass.

 

best thing youll hav to do is take off the trim, and if the rust is going under the windshield and gasket seal stuff, youll hav to take that all out too. then sand it down to no rust as possible, check up inside too for rust if there is, sand there too. and if it didnt rust all the way thru, spray rustoliums rusty metal primer on it, inside and out,then either spray the topcoat color of your choice within 45 minutes or wait two weeks,then sand and paint your top coat. then another 2 weeks before you can put the windshield back in. my windshield is leaking and i hav to do that before i change my cracked windshield,so the new one seals.