Andrew,
thanks for the great description of this procedure, I have some rust in one of the
corners under my seal and have been contemplating doing the same but wasn't sure
what I would be getting into.  Soon as it warms up I'll give it a shot.
However, I've been told that Bondo is really not a great choice for patching rust
holes as it tends to absorb moisture and therefore the hole you patch with bondo
is likely to rust again rather quickly.  I can confrim this experience with lower
rockers on an old bay...Does anyone know anything about using Bondo for such an
application as patching rust holes around window seals?  Better alternatives?
Also, does pulling rear-most side windows follow basically the same procedure?
Mark

Andrew Martin wrote:

> The windshield on my '87 Syncro has been leaking for quite some time and I
> finally decided to do something about it.  Upon close inspecting the old
> gasket, I found that a small rust spot was developing under the seal so I knew
> that it was going to be a little more complicated than just installing a new
> seal.
>
> First I ordered a new German windshield seal from The Bus Depot for $49.95.  I
> chose to use the smooth California model to eliminate the ugly plastic
> moulding that used to look like chrome and now looks like sh*t.  When it
> arrived I went to my local NAPA store bought some plastic body filler (Bondo),