re: do cheap rust repairs work?

[Jay Negrin <jmnegrin@domain.elided>]

last week Andrew Watry asked, and I am sure others have answered (I am
about a week behind in reading at this point):

<<Just from asking the question in the subject line I ought to know the
answer.  But here's the specifics: plenty of GTVs and Berlinas have rust

around the windshield, particularly US 2000 Berlinas on the upper part
where the windshield meets the roof.  I'd like to fix my Berlina in this
area
(which is bubbling nicely and leaks water into the interior through the
headliner), but despair of the hassle and expense of taking the glass
out
and doing a full-on correct welded-metal rust repair.  The car is hardly
worth it.  Also, glued Berlina windshields are hard to find.  The cost
of a
new windshield, plus the glass shop's time, could easily hit $500 in
Berkeley.  Heck, I can buy a whole Berlina for that.

Has anyone had success with a well-done bondo or other type of repair,
perhaps even without removing the glass?  I'm obviously not looking to
achieve a concours Berlina, but want something presentable that might
last five years or so.  If I could fix it this way I'd be happy to get a
Miracle
paint job that would make the car less disreputable.  Any useful advice
or experiences appreciated.  I realize I'm probably hoping for too much
...>>

My tuppence, on an Alfetta GT windshield area rust repair.  Several
years ago, I had SERIOUS leakage in the windshield area.  I, wrongly,
thought the leak was at the top, cuz that's where I saw drops coming in
while driving in the rain.  Windshield came out, and found that rust was
along the bottom 1/3 of the cowling and area surrounding the
windshield.  Over to the body shop, and the area was cleaned as
completely as possible to get the rust out.  (Yeah, I know, you only get
what you see, and the rest comes back later.)
The area that was 'gone' was built up with Devcon, an epoxy compound
with metal in it.  The body shop guys shaped and formed it so the
windshield would fit and seal.  It continues to seal.  The areas that
couldn't be cleaned of rust were liberally applied with the blue goop
that "eats rust".  Body shop and windshield guys both say that the fix
is temporary, and that you don't get rid of rust, short of an r&r of the
offending piece.  I hope that I have slowed the process down to a
manageable pace.  Considering this is So Cal, and it rusted that bad in
a dry climate, I shouldn't cry too loud when the time comes for a
vehicle replacement, eh.

As always, YMMV

Best of luck

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