Hey Guys,
I took out the trim on my front windshield of my 69 Camaro and found the top channel where the molding clips are is rusted out almost all the way across. The rust is in the channel and comes right to the bend where the roof starts the roof part feels solid. My question is has anybody fixed or replaced this area and does anyone sell this as filler panel? Any information or pictures would be helpful.
Thanks in advance.
Larry


[This message has been edited by Thibokid (edited 05-09-2002).]

I'm looking into the same thing also right now. It looks like you and I will have to buy a full new roof skin that has the curved channel. I saw on this forum that Rick's is offering them, but I haven't tried to order one yet. I also have pillar rust through, and it looks like I will have to have the local sheet metal shop help me fabricate some patches.

If the rust is just in the channel, all you need to replace is the rusted portion. It has to be easier than replacing the roof. When I did mine, I cut and trimmed new sheet metal to fit, cut out the rusty stuff, and welded in the new piece. I have to tell you my car was completely stripped and blasted before I began. Also check where the windshield meets the dash. This is also a nasty spot.

My top windshield channel was shot also, My A pillers looked good and I took a couple inches of the roof across the front edge where roof begins to bare metal to make sure the roof did'nt start to rust to bad also if your roof looks good, here is what I did to fix the channel.
To begin with I did this project in 2 parts driver side then pass side I did it this way because once you cut out the old rust out the roof on the front edge has no support.
Measure the channel if I remember correctly it was somthing like 3/4 x 3/4 inches. Make a mark in center of windshield channel I used a air powered cut off wheel went down about 1/8inch from roof line into channel and made a cut from driver side to mark in center of channel if its real rusty like mine was you can use a hammer and chisel and remove whats left of the windshield mounting surface if this area is good metal then you will just cut out the rusted part of channel. I used a small cut off whell in a Dremmel to make the vertical cuts on the ends by this time you should have a long rectangle shape hole that has a curve to it.
I had some 20gauge sheet metal so I measured the length of the hole in roof then added about 2inches to that, then say the channel is 3/4x3/4inches add the 2 together plus another 1/4inch remember you can always grind it down to fit cut out the patch then draw a line down the center of the patch from end to end now you can start to form the L shape of the channel using a hammer and bench vise put the metal in the vise line the jaws up with line drawn on metal and begin rolling the metal over just do a little at a time from end to end until completly bent into shape. To form the curve I just cut some narrow pie shape cuts into each side until I got it to curve into hole in roof just right now just use a angle grinder with a flap disc 60grit to take off metal along top of patch until it fits snug in the hole you can also cut the length to line up with mark in center of windshield at this time. Now is a good time to paint inside area of hole with POR15 then just take your time and spot weld patch in then come back and final weld I used a Lincoln Mig welder with gas and .023 size wire be careful not to get one area to hot or you will have a warped roof to complete this side just grind down all the welds and you will not even tell you put a patch in.
Oh yeah before you begin note the location of the little studs that the molding clips attach to also take note of how far down into the channel the studs are mounted as this will affect how close the molding sits to the windsheild once installed the new studs can be bought from Ricks First Gen and they screw in. You could also find some thin gauge sheetmetal thats already bent into a 45degree angle or find someone with a sheetmetal brake and have it bent. Well there you have it I did both sides in 2 weekends and NO more leaks have any ?'s feel free to Email or ask here.
Jeff