winsheild removal, rusty cowl, black rubber and Frit Options

[sean_v8_914]

I used to tie a guitar string onto two pc of broom handle or just wrap each end around a screw driver untill the Matco guy sold me this nifty tool for $30 bucks

[sean_v8_914]

here is a pic of the trim hilding clip. you only need to cut the small round pin in the center

[sean_v8_914]

A pillar clip locations

[sean_v8_914]

bottom trim clip locations

[sean_v8_914]

trim should just fall out in one pc still connected

[sean_v8_914]

here is how that window cutting out tool works. your other hand goes on teh round vertical handle to hold it up straight as teh other hand pulls the "T" handle along the glue bead
putting the car in teh sun for a frw hours to get the butyl soft makes it easier

[sean_v8_914]

do not nick the glss or try to pull teh window out untill you have completely cut away teh butyl rubber seal bead. 914 windsheilds are very easy to crack. a chip on teh edge will start to crack if the glass is flexed

[sean_v8_914]

wire wheel...went a little crazy.I pick away at teh cowl gap fairly deep to remove rusty flakes first
the deep pitting rust must be neutrilized. I use SEM rust mort first. let it set on bare metal fro a day. keep it wet and out of teh sun. DO NOT ALLOW IT TO DRY. If you want to stop for teh day, wipe it off with a damp cloth.
once teh rust has turned black deep into the pits, i switch to Ospho or PPG DX 530. leave this on all night. teh metal will look dull grey when it is well etched then wipe with damp (almost dry) cloth. blow dry, let dry for a day, use some sunshine now is OK.
do not be tempted to grind down rust to clean metal. it will be too thin. let the chemicals do their job

POR 15 is applied ONLY on teh rough areas of rust pitting. POR 15 does not stick to clean metal but the etching process described above will make it stick if you get a little sloppy with its spread.

[sean_v8_914]

for some reason teh photos make it all look so clean. it was rusty and nasty. the stuff in teh pitted pores is what makes it bubble up in a year. I hate to see that crap.

[sean_v8_914]

tape lines and over spray are so skanky. there are two 10mm bolts. one on each side of the ventilation box. remove then and you can drop the box and slip in a cardboard mask. the black mesh will make the fresh coat of yellow POP. I removed teh window squirters and wiper hardware. it really takes less time than sanding around it and masking it off.

[sean_v8_914]

POR 15 is only on the rough metal. I did use it heavily in eh cowl crack. some cars need the cowl gap completely dug out. if you see rust or deformation of the cowl gap seam sealer from inside teh door jamb then you need to remove it to kill that rust also. Peter's car is OK so teh long 3 day soak of chemicals shoujld kill it all without removing the buttom of this seam

[sean_v8_914]

get under these corners with a mirror and teh above described chemical processes, then POR 15 the underside

POR 15 is nasty, mask any drip zones

[sean_v8_914]

under teh seal trough rust

little rust incubator. often missed

[sean_v8_914]

reg

[sean_v8_914]

the seal from dash to window was petrified. 914rubber.com sent me a new one.
did I mention that this car is getting all new seals from mikey rubber guy AKA Mark Whitesell
since the cowl will be so nice, the rubber seals all new...how could I leave the dash so nasty.

remove steering wheel
remove dash gauge face with 3 gauges still in place
pop the 2 outer gauges from their rubber rings
this is to help remove teh dash topper

[sean_v8_914]

these 2 plastic dash nuts are a bitch. a short 13mm wrench is a blessing here

[sean_v8_914]

sand teh POR 15 with some 220.
then I use Wurth or SEM etching primer on bare metal and over POR 15.

[sean_v8_914]

sand etching primer with 220 then I coat with 2 part epoxy primer then sand it again

[Rusty]

Sean, this is GREAT info!! (IMG:style_emoticons/default/beerchug.gif)

[sean_v8_914]

sand epoxy smoooooth with 320. stay away from edges. do not sand thru. you must go back and add primer if you go thru.
I maked off teh cowl to paint the defrost vents black.
then once dry mask them off to spray contact cement for dash pad foam and vinyl cover