Well, unfortunately as good as the lower portions looked, the upper frame and driver side need replaced. My #2 and #3 body mounts and rocker channels look beautiful. Amazing the top side can be this bad. Here are the before pics. I will continue to update this thread as we go along.

 

Here is the repaired driver side upright from today.

 

Looking good.

 

Hi 69,
"Amazing the top side can be this bad."

Had the windshield been replaced at some point?
Sometimes if the new sealer wasn't done well it can lead to what you're seeing!

At least you're taking care of it!
Regards,
Alan

 

How are you making sure the frame stays straight? I would have expected you to build a jig so that the top corners stay in the same place with the channel cut out.

 

Great work and thanks for the photos!

Here is a link to a repair "how to" by Willcox, great write up which might be useful:

http://repairs.willcoxcorvette.com/w...stallation.pdf

 

Thanks guys. Didn’t mean to imply I was doing the work. Way over my level of expertise. Guys that are painting the car are doing the work.

Zwede, will ask the question. He is doing the top frame today so should have more pics later.

Alan, there was definitely a windshield replacement in its past, but no idea when. I have owned the car since 2001. Through some interior work I did, I knew there was filler in the top frame on the right side. Amazing how much worse it looks when stripped down.

20mercury, thanks for the link. Great illustration!

 

Wow, that brings back memories of a couple years back. Glad it's over and done. The stainless mouldings that cover the top of the frame are also to blame for the rust there. They have to be sealed from water penetration. One compromised spot and water gets in and can't get out. Especially noted where yours is rusted on the backside of the channel, this is from the chrome/stainless trim leaking. It's a real bitch to get sealed up. I vowed to never let mine get wet.

 

I'm still amazed at the condition my windshield frame was in after sitting out in Michigan's weather for 15 or so years.

Attachment 48354624

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Attachment 48354628

 

Wow! you are living right!

Why good you think? I go back and forth between trying to seal up every last microscopic leak point and thinking maybe less sealant and possible points for it to evaporate to the inside of the Corvette is better? Any insights?

 

Years ago we made a jig to hold the windshield frames in place while welding... We love it and it's a royal pita to install but when we are done we know the parts are in the correct position. (you can see this jig in the pdf I did years ago). We're going to start doing this exact same job tomorrow in my shop... we don't know what the extent of the damage is to the customers car, we've not seen it yet but once we get the trim removed we'll see where we are... and then install the jig.

It looks as if they remove the outer portion of the upright and welding part of the new upright to it. Typically we'd replace the entire upright and spot weld the corner in place. Actually all our welds are done with a spot welder vs a tig or mig (except when you have to install the entire upright). We do it this way because it requires way lest work in doing the finish product (no grinding welds) and its the way the parts were installed from the factory. I just blew up the picture and yes, that's exactly what they did... Without welding some sort of fixture to the frame how can they be sure the frame didn't move? I'm with Zwede on this one... that's not the way to do this job unless they removed the supports before you took that picture, but I sure don't see any supports in the picture with the outer skin pulled off. Possibly (and I hope) they took measurements before they cut that loose because if they didn't that could be a major issue when they go back together. If it moves 1/8" nothing will fit....

One thing that we've noticed over the years, people will get a small leak and will silicone the moldings to the windshield.... Huge mistake. If you ever see a car with this done you can bet they have a windshield frame issue because the water from around the moldings has no place to go.... it actually increases the failure time of the existing windshield frame.

Go read the PDF posted above and know that the new production of the windshield frames has been correct and they fit like a glove now.

IMHO
Willcox

 

Finished the top and side posts. Unfortunately found some on passenger side just under top of fender. Was able to get it from the inside in a pretty cool way, without having to remove front clip.

 

Hi 69,
Well, THAT was pretty ingenious!!!
I can't quite tell from the photo... were you able to get to ALL the damage from below?
If so, well done!!
Regards,
Alan

 

I had a body shop next to me in hartford. Couple of Jamaican guys regularly replacing roof on rollovers. They start with square and diagonal measurements from the straight clip. Cut the pillars a bit long and shorten then a hair at a time till the measurements fall in place.

 

Alan, yes when they told me how they were going to do it, that was the first thing I asked. But he said they could get to it all. I thought the same thing. Don’t think I have seen anyone do it that way before but these guys continue to impress me.

Derek, pretty cool way!

Chuck, you sure did get lucky with that birdcage. If there is one thing I have learned from this is no matter what some parts of the cage look like, there could be rot elsewhere. You are looking good!

 

Just a point. Never ever leave the tops off your Vette, if it rains water gets on the dashboard and will get between it and the windshield and stuff starts to rust fast.
A buddy has a duntov winning 67 convertible his sister and her husband borrowed the car and left the top down in the rain. When they brought it back he saw moisture on the very bottom of the windshield.
He pulled the windshield and dashboard to dry it up. If he hadn't over time it could cause real damage. It's alot of work but he was right no matter how stupid some thought he was.
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What happens with the VIN tag? Looks like it went with the drivers side pillar.

 

Omg here comes the VIN tag issue AGAIN!
Crush the car, set it on fire because you can't do that.please live in reality, those laws we're never intended to keep someone from repairing thier car.

 

When replacing the driver side pillar the vin tag must be transferred to the new pillar.

The issue is the Rosetta head rivets which are controlled in Indiana and Federally... You can use pop rivets, but it's a compromising issue that is something that is dealt with state by state and federally. While my brother is a lawyer, I only play one on TV... (lol)... I don't know the law on this so before you put standard pop rivets in place you may want to check. Honestly I don't think any law enforcement agency pay's that much attention to this if an inspection is needed.

Number one, finding the Rosetta rivets is next to impossible, (and illegal) number two... will the standard rivet head be a compromise... That's something that you should check with your local authorities.

 

I've seen guys take steel rivets and used a grinder to replicate the shape. I believe someone in Hemmings sells the rosette rivets.many cars are legitimately repaired every day.