i know this sounds bizarre to most of you, but i have used JB WELD to fix
small rust holes or pinholes and the stuff works great!!  its epoxy-steel based
and the stuff has never let me down.

i pulled the windshield out of my ex 78 westy and fixed the small pinholes in
the metal with JB Weld and sanded it all down and painted it w/ POR 15
(roger sizzlers favorite) and it held up great

chris
roger, do i get a comission for mentioning POR15?  ;<)

In a message dated 2/20/08 4:06:50 PM Eastern Standard Time,
scottdaniel@TURBOVANS.COM writes:

> Hi,
> The first number that pops into my mind is 'about 500 dollars'.
> And it depends of course,
> On how bad the rust spots are,
> How well they get repaired and the areas repainted,
> And you should use a new windshield seal,
> And sometimes you want a new windshield which is a 200 to 400 dollar part.
> So it could go up to a grand for a full on deluxe job.
>
> Chris is very right about bondo being a very low grade repair.
> IF there are holes clear though the metal, welding then grinding back to the
> original shape is the only right and real repair, and the 'inside' side of
> the metal needs to be painted or protected from rust after that too.
>   For a 'real restoration' on a valuable vanagon, having the dash out would
> even be 'the real way' especially if repaired by welding.
> Fiberglass doesn't stick to metal very well.
> There are epoxy steel materials just for car metal work however, and they
> work very well.
> The one I use is Duramax 4125.
> It's like steel when it cured. It's professional grade stuff, not anything
> you'd get at a FLAPS.  You could leave the dash in and do all work from the
> outside using this material and get a darn good job this way also.
>
>

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