So I've decided to replace my windshield frame (see pics below). I went to the local corvette boneyard in Phoenix today (20th st. auto) and picked up a perfectly rust free windshield frame off an '82 for $150. I had them cut it as low as possible (below the VIN) and they did a nice job getting it out. They also cut it back 12"-14" into the t-top, giving me plenty of options on where I splice it in. I oversaw the whole operation and it came off a real straight car. They wouldn't cut it out till I ok'd the one I wanted.

As you can see from the pics below (sorry for quality of some - focus issues but you'll get the idea) my corners are really bad, especially the passenger side. The area where the t-top attaches into the top frame and the whole underneath of the top frame is badly pitted as well. To my surprise there is no rust below the VIN area or into the section of the birdcage that goes down into the door frame.

I would like to get some advice, before I cut anything, of the best way to go about this operation. I have a Millermatic 175 gas shrouded mig welder and am confident in my welding abilities. My biggest concern is not changing any of the geometry so that the T-Tops, windows, etc.. all line up when I'm done. I have even considered "piecing" it in to protect the current dimensions. I have a plasma cutter so I can cut smaller sections fairly easy. I've done some measuring and have some ideas how to set up some supports and jigs in order to keep things stable, but wanted to get some advice from the pros out there

This is clearly a major operation and I want to go into it armed with the best advice possible. Thanks guys!!!

 

C'mon, where's all the great body guys out there? I want to get on this tomorrow AM

 

Take many measurements. All possible axis. I have a digital level which helps. It isn't all that complicated, just measure, measure and when you think you got it, measure again. If you have any doubts, just tack it together and assemble everything dry. Pillar trim, weatherstrips, etc. Roll up the door glass, put t-top on and check it out. Then if all looks good, weld away, but don't overheat any sheet metal...don't want to warp anything...lol

 

http://forums.corvetteforum.com/show...aint+bird+cage

Check this link out, the guy did it like a pro! He probably did it better than any pro I have seen. It has a lot of info and a ton of great pics!

Good luck!

 

Thanks guys. I plan to take lots of measurements and lots of pictures throughout the process. I've decided to splice into the T-Top bar where the front T-Top mounts go (in the center). This way I can screw the mounts in on both sides before I tack this section in. The A-Pillars will be a little tougher, as there is no reference available like in the "T". But as Big G says, measure, measure, measure I'ts kind of like what my carpenter buddies all say "measure twice, cut once" As far as the welding goes I will make lots of small spot welds, allowing for appropriate cooling as not to warp the sheet metal. Thanks again guys!!!

BTW: Welcome back Little Jake!

 

 

Any advice from the morning crew before I head out to the garage? I have a plasma cutter and a welder calling my name out there.

Besides Big G's measuring advice I think appropriate bracing to the car so it doesn't compress or separate once I cut through the T is vital, and I will be taking measurements before and after I make the cuts to ensure nothing moves. I plan to level everything before I start to have the best starting point I can get.

Monty - I saw your corner replacement thread. I had heard some of the after market corners wouldn't fit real well which is why I decided to go the junk yard route. You did a nice job

Even with the dry climate here there were a lot of rusty windshield frames on some of the cars in the boneyard. Fortunately I found a nice clean one and they had a good selection. Probably not the case in most geographies. Nice that the '82 frame is identical to the '69.

 

After reading an extensive post over in the C4 section, the only thing not mentioned already is this:Once you are sure that everything fits correctly, make sure you protect all the exposed metal. The post stated that often times it can be something simple like a scratch that exposes the metal which starts the car down the road to rust damage. They noted that even areas that the window, or the sealant will cover must have at least a coat of primer on it. They stated that this was because even though it appears sealed, it is not really. This means that the metal will begin to oxidize again, and with the window in place, you won't be able to stop it. Hope this helped.

 

When I did mine I cut between the front t-top mounting bolts. This gave me a fixed location and dimension that was easy to maintain.

I replaced everything including the door pillars sao I can't provide advice as to where to cut down there.

Have fun.

 

Wow - missed this post til tonight.
I did EXACTLY what you are doing.
If not too late, the most important measurements are:
Center-top edge of WS frame back along Ttop bar to where FG starts
Sides-top corner of WS frame to corner edge of FG (top of side window glass)
Sides-front pillar length from top of corner to reference under cut (put small notch with file)

I cut mine just above the VIN - to retain VIN placement. I'd suggest the same if possible.
I put some small pieces of steel - pocket welded into the verticle pieces
to act as reinforcing inserts.
The Ttop bar I decided to cut at the very rear.
When cutting the donor to fit, always try to cut big - then use a flap
wheel on a 4" grinder to slowly shorten the three ends to fit the measurements.
I have a bunch of archived posts - but pics are probably red Xs.
I'll try to dig some up and post here.

 

Hey NHvette, I ended up spending the whole day yesterday doing a 20 minute "honey-do". You know the one I mean, just like the fuse change in a vette leading to a frame-off restoration? Well this started as a simple sprinkler repair. Needless to say I never did get into the garage

I appreciate your feedback - I'm going to try to get started today.

 

Cool - you can look through my threads, but I'm afraid all of my pictures
from that time period are gone ... from a HD crash.
http://forums.corvetteforum.com/sear...archid=2021271