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Bird Cage Rust, now what?

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Old Dec 25, 2025 | 12:29 AM
  #21  
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With my new interior resto I’ve almost got the dash out ( one corroded side screw left) so see how bad what I have is.

Heres 25 years of garage kept by the PO ( friend who’s older ) and never even thought to look behind.

some one tried fibre glass fixing the corners. The lowers have small holes. As for now, it’s blow and suck everything out, wore sheep and convert. I may get a while frame from a doner and just do it that way vs piece. Need to be smart and don’t want to ruin from clip.



Crazy part is it’s JUST the corners. The whole middle is tip top. Not even surface rust.
Crazy part is it’s JUST the corners. The whole middle is tip top. Not even surface rust. Below I can’t punch through.

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Old Dec 25, 2025 | 03:31 AM
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Hard to tell how extensive your rust is, but if it is just the corner you can do it without disturbing the front clip. Your inner corner skin has rotted through, mine was no problem at all, but here's what was left of the outer skin once I had removed the inner skin.



This is what it looked like when I cut out the rusty part of the outer skin



Then put in the new outer skin.



and refitted the inner skin




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Old Dec 25, 2025 | 10:57 AM
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Ouch. Yes I’m expecting the worst and hoping for the best. What blows my mind is all of this was stopped in this state over 25years ago and my friends dad ( PO ) never suspected a thing. Just enjoyed the car and took care of the mechanicals.

So far that’s the worst but looking through I can see more holes ( again just corners ).

the car doesn’t see rain and won’t so I’ll come up with a plan.

thx for posting the pics. Your work looks great!
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Old Dec 28, 2025 | 05:09 AM
  #24  
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If the rust was bad that area behind the kick panel would be a lot worse that what I'm seeing. I would look up under the dash towards to base of the windshield and just keep looking until you've seen most of the windshield frame. I don't think there is a serious rust issue here but if it were me I wouldn't stop until I knew for a fact there is no problem. My first course of action would be to remove the T-top trim and get a look at the windshield frame,there are areas on top of the frame that water can collect and sit there.
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Old Dec 29, 2025 | 04:41 PM
  #25  
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Originally Posted by ukjohn
Hard to tell how extensive your rust is, but if it is just the corner you can do it without disturbing the front clip. Your inner corner skin has rotted through, mine was no problem at all, but here's what was left of the outer skin once I had removed the inner skin.



This is what it looked like when I cut out the rusty part of the outer skin



Then put in the new outer skin.



and refitted the inner skin

I just finished doing similar on my '71 but I did remove the rear tip of the fender.

How did you weld the outer corner piece on without removing at least some of the fender??
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Old Dec 30, 2025 | 06:42 AM
  #26  
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You can weld the areas I've marked in red, but not the yellow area. I applied some epoxy along the yellow area from inside the car to provide a bit of strength. I felt this was acceptable and preferable to removing some or all of the front clip.


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Old Dec 30, 2025 | 08:48 PM
  #27  
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Not too bad around the mount. Others will chime in with help
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Old Jan 5, 2026 | 05:06 PM
  #28  
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Originally Posted by ukjohn
You can weld the areas I've marked in red, but not the yellow area. I applied some epoxy along the yellow area from inside the car to provide a bit of strength. I felt this was acceptable and preferable to removing some or all of the front clip.


exactly what I needed to know. Thx! There are some great panel seam products out now.
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Old Jan 18, 2026 | 02:49 PM
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I wanted to follow up for any future readers of this thread since the opinions varied a bit. I pulled out all the trim and glove box to have a look. I also shoved my borescope where ever I could to have look. I was already doing some wiring work so it became a "while I am at" thing. I am glad I did for the peace of mind. Any rust present was all just surface rust and there really wasn't even much of that. I treated what I did find with rust reformer.

As for the spot on the base of the a-frame, it must been just a chip in the paint and not bird cage related.
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Old Jan 18, 2026 | 03:35 PM
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Good news, glad to hear it.
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Old Jan 18, 2026 | 08:31 PM
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That’s great news, now go buy a lottery ticket!
You might think about picking up a can of POR15 and coat the areas that you can get too.
It comes either in a rattle can or in a can that you can brush on.
I used the brush type, it worked really well and will seal the windshield frame forever.
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