I've got a 91 XJ that I've been working on rebuilding. Nothing fancy, but a more fresh start.

Needs a windshield. Had a bad rust spot/hole on the main cowl panel just below the windshield on the driver side that ive managed to patch and weld thinking thats why ive had 4 different auto glass places deny doing the work.

issue now, as I look closely, it looks like there are rust bubbles under a black layer of pain right next to the urethane adhesive holding the windshield down. It's not a ton, but certainly there.

questions.

1. Would the rust bubbling under the paint next to the urethane adhesive on the flange point to the liklihood the urethane has the same issue underneath?

2. If not, would the presense of those spots along the flange have any effect on a new windshield?

3. If yes, then what's the preferred prep of that flange for a new windshield? If I have the strip the windshield out, cut the old urethane and go to bare metal along the flange, what am I going back to? Just a 2k epoxy primer/sealer? Do they want paint? I'm assuming it isnt bare metal.

any help is appreciated. Just need a windshield so it can go for the 16 year old driving test.

 

The repair needs to be the same as factory regarding paint / sealer. The hole will grow as you grind out the rusted metal. Pita job, do it right, do it once. Good luck

 

I totally agree with above. Must be factory standard

Good news. You CAN do the whole job yourself ! Use original screen (if you cannot get a new one, but you should be able to)

Over here, most windscreens are fitted by mobile installers

In your case, you should remove your screen, prep, and have a mobile installer do it, or it can be done DIY

Step 1) The outer screen rubber is hard to get, but cosmetic. You REALLY need a new main seal, nothing else will suffice

Step 2) To remove urethane screens such as in the XJs, I use wound steel guitar strings, poke them through, leather gloves, saw them along, its hard work, probably break a couple (of strings), be careful on the corners, or you will say the word ****

take screen out, remove all urethane, make metal repairs, be mm perfect on lip, 2 pack paint prep

I have a pic of the stuff "my guy" uses, he is vastly experienced specialist $100 cash in my driveway, including materials, got onto him through a mate who had a panel shop, got this guy in to do screens!

will check my pics

 

Alright, yall were right and thank you for the push! had a guy come by and rip out the old windshield. While this hole was the primary issue I saw, the assumption was right and rust had crept under the urethane at the bottom edge.

Luckily, nothing was rotted out entirely so it was wirebrushed and scraped clean in the areas that needed it. I did a round of ospho on everything that was left bare and my windshield guy said he'd handle priming the pinch weld area before new glass.

Window is in and trim is back on. Now we just wait and see if we have any leaks.

Steering and suspension are next on the list.

 

Nice! On to other fixit jobs you go. Happy trails!