so despite the weather and the prospect of WSB on tv from assen i braved the elements and got outside today to tackle the windscreen surround which was pretty scaby but not as bad as some i've seen/worked on
passenger side bottom corner was the worst plus some cruddy looking scabs across the top edge of the roof...
pic 1. first job was to chop the lip off that the screen rubber sits in and weld a new bit in.
pic 2. next job to build up the lip that joins to the top face. note the abundance of waxoyl under there, although this car does have rust it has been largely saved by a good layer around most areas...
pic 3. a new plate made up, joggled and welded in flush (ish) then ground off level so minimum of filler will be needed
pic 4. a made up a cradboard template first off to be sure of creating the same curve before chopping it all out, job done. a simple thing but helps to be sure the screen will go back in
pic 5. the scabs were ground off from the roof to reveal a few holes, surprise surprise.
pic 6. i simply welded in the holes on the roof lip rather than go to all the bother of chopping then out & plating them. all rust was removed so it was just a case of gradually plugging the holes then smoothing off the welds.
are you using the new toy, the knotted wire wheel to get the rust out of the roof and pillar holes?
if so, it makes a really good job of getting it all out the deeper bits eh, a normal wore wheel wouldn't get in there, and a grinder takes too much good away with it, so good tool, gotta get me one of those i think.
my technique for welding a hole up is to ignore the hole.
start to weld around the edge but well away from the edge, if you get what i mean.
then once you've got a circle of weld you have a solid base to bring the weld pool inwards and you end up with a blob of solid weld without having to burn through the tender metal.
just don't try to do it all in one go though!
I thought I fitted something called Superpro bushes from a company in the UK. Had no problems with them and they were a bit cheaper than powerflex. Got them via ebay. I'll see if I can find a few more deatils if you want?
Last time I rebuilt my blue Sud, back in 1988 I filled some of the minor rust holes with weld and made sure I could get some paint and waxoyl on the back side of the panel, those repairs are still good today.