rust in safari windows in the roof

**bruce p38** · 26th February 2013, 10:20 AM

My wifes Discovery One has the beginnings of rust in the edges of the safari windows in the roof at the back. We had them fixed once and it came back . Any comments or solutions would be greatly appreciated

Many Thanks

Bruce p38 and the Missus

**SLOWBOAT** · 26th February 2013, 04:43 PM

Have the rust cut out and new metal welded in. Have the metal all around treated correctly, etched, primed and painted.
Re install windows with NEW rubbers and then check for water leaks (check and test extensively) with the roof liner out. If all good then reinstall the head liner.
The reason most rust is because they are leaking very minutely and so the water sits under the rubber and starts the rust. If they are sealed well then all should be good.
Good luck with them as they are a bugger of a job.
Cheers

**bruce p38** · 27th February 2013, 07:29 AM

Thanks for your advice. Sounds like a crappy job but jobs done well usually are

Thanks Again

Bruce p38

**Grahame Roberts** · 12th March 2013, 02:34 PM

The key to the job is to ensure that a thick gooey sealant is applied under the rubber. Not having any sealant will mean that the rust will come back.

**yannpiat** · 12th March 2013, 09:07 PM

I actually just did both of my alpine this weekend passed. Mine were quite bad with some major holes. I did a home job which was pretty easy seeing as i have never done any body work.

I started by cutting the rust affected areas out with a grinder and any little specs of rust were grinded off with a Dremel.
I then coated grinded and dremeled back areas with rust converter incase I missed any.
Once converted they were primed.
I then cut some gal sheeting to replace cut areas.
These new pieces were bogged/Fibred in with motospray metal fill. Leaving it very solid and like one piece again (contains metal particles)
I then reprimed again and used regular motospray body fill and spray putty to smooth the outside surface (inside not worried about as it will be covered, did spray and seal my work though)
Once all sanded I primed again and painted with white knight kill rust paint (doesn't match the original paint, but may respray the whole car soon).
I then cleaned all seals of old sealant and scrubbed clean, I left them to dry and then used windscreen sealant in each seal before reinstalling.

The whole job took me 2 days allowing for correct drying times etc. the sanding wash rushed a little as I needed the car finished by Sunday night and could have been done better, but I'm not complaining as the windows don't leak anymore and the work will probably see the car out, If not it only cost me roughly $100 to do (better than the $1200+ quotes I recieved)

Plenty of photos during the process. Will upload tomorrow.