I'm going to look at a 78 Pace car this week and after reading some old posts about the possibility of rust in this area, I want to check it out but don't know how to go about it and if the owner will get upset if I ask to take some things off. Is there a first step to take that doesn't involve removing anything, and then a second step if there is small rust, or should I insist on removing panels right off the bat?

 

Hello,
Probably the first thing you CAN do is find the truth about where this car has spent it's life.
Cars from the South and West generally have less rust than cars from the Northeast and Upper Mid-West. Or maybe no rust.s about what there is to see.
You can look through the windshield from the outside and get an idea about the hinge pillars by looking at them with the doors open.
Some close up photos will get you opinions galore.
Regards....

 

Most sellers will be reluctant allow any disassembly but removing the kick panels and looking at the #2 mounts and removing the windshield pillar trims are easy and will give you some idea but unless you go deeper, there will always be some doubt.

 

The birdcage itself may well have surface rust/dust and be just fine. It's rust "jacking" that indicates problems and a high cost to fix. Rust jacking is when the metal has become swollen and flaky because the corrosion has permeated the metal.

Take a flashlight and borescope and you won't have to do any disassembly. First remove the t-tops and examine the chrome & stainless trim of the upper windshield trim and entire T-structure (center and rear). Rust jacking will cause the trim to lift out of place. You may also see rust bubbling in the chrome of the corner and rear pieces - a little roughness isn't much concern, you're looking for signs that the metal under the chrome is breaking down.

Next, examine the windshield frame from the outside. Using the flashlight, look at the structure through the glass edge and under the stainless trim. Look at the metal above and below the VIN tag - it's mounted directly to the birdcage. Again, rusty discoloration isn't a concern - you're looking for flakes and holes.

Thread scope over and down the hinge pillar to view the body mounts. Any water leakage around the windshield tends to travel down the sides and onto the #2 body mount bolt. Some surface rust, again is to be expected; you're looking for lots of flakes and a bolt head & washer that's eaten away. I don't know if you can also thread the borescope upwards toward the windshield, but it wouldn't hurt to try.

Don't forget about examining the frame corner in front of the rear wheels and the "kick ups" where the rear trailing arm suspension attaches to the frame.