Birdcage Rust
Thread Starter
Racer
Joined: Jul 2004
Posts: 287
Likes: 0
From: Baton Rouge Louisiana
Birdcage Rust
After following many of the threads on frame and birdcage rust I decided to rake a little closer look at the '68 vert I have started restoring. The car is pretty clean for the most part, but I did find some surface rust on the windsheild header and a small area rusted through on the right windsheild pillar. What is required to repair these two areas?
TIA
Jeff
TIA
Jeff
Last edited by '99 Feather; Jan 8, 2005 at 12:47 AM.
Safety Car
Joined: Aug 2001
Posts: 4,883
Likes: 11
From: North Easton Mass
The windshield should probably be removed to thoroughly examine the area, especially if you have a rust-through. The birdcage is the only thing that will protect you in the event of a rollover so it's important that it be secure. If the rusted areas are small they can probably be welded or have patches welded in. I'm in the same boat with my windshield frame (maybe worse) and I don't want to take chances with safety items.
Rick B.
Rick B.
Burning Brakes
Joined: Mar 2004
Posts: 1,100
Likes: 2
From: Charlotte NC
If it is minor, then just wire brush it down, and seal it with a good anti-rust product like POR 15 or Encapsulator. The hole that is rusted through might could be just welded up if you can get the metal cleaned up. Just be sure to be thorough! You dont want to have rust sneaking around in there later on. I would suggest removing the windshield, too, just to be double sure!
Race Director
Joined: Sep 1999
Posts: 11,360
Likes: 382
From: Plano TX
The windhsield has to come out. You will have more rust underneath. It's not hard to pop the windshield out and it can be done without damaging it. Call some glass companies in your area. They will come out and remove it and then come back later and re-install.
Once the windshield is out you should grind all the rust off with an angle grinder until everything is nice and shiny. At this stage you can see where you need patches. Cut the bad sections out with a cut-off wheel in rectangular shapes. Form patches from 16 gauge sheetmetal to just fit. Use a magnet to hold it in the hole in the cage you cut. Weld it in place. Grind down the welds. If done properly the repair will be invisible and stronger than new.
I did all this on my 71 a few years ago. One VERY important thing: Get a quality welding blanket and cover the interior. I didn't at first and thought it was enough to just cover the interior in regular blankets and towels. Welding set the car (blankets and towels) on fire. Luckily no damage besides some scorched towels.
Once the windshield is out you should grind all the rust off with an angle grinder until everything is nice and shiny. At this stage you can see where you need patches. Cut the bad sections out with a cut-off wheel in rectangular shapes. Form patches from 16 gauge sheetmetal to just fit. Use a magnet to hold it in the hole in the cage you cut. Weld it in place. Grind down the welds. If done properly the repair will be invisible and stronger than new.
I did all this on my 71 a few years ago. One VERY important thing: Get a quality welding blanket and cover the interior. I didn't at first and thought it was enough to just cover the interior in regular blankets and towels. Welding set the car (blankets and towels) on fire. Luckily no damage besides some scorched towels.
