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Thread: Above windscreen rust

  1. #1
    Join Date
    Sep 2015
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    In the shed or 1000km from home
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    Above windscreen rust

    Hey folks,

    I have some rust that i am fixing up above my windscreen in a Disco 1.

    The rust is not really behind the top windscreen seal but an inch or so up from it.
    I cant figure out why it would rust there? There is nothing to trap the moisture there. I have seen other discos rust in the same spot.

    There appears to be a hollow cavity behind the outer layer of roof steel before some type of inner layer. I can even see some type of little 'holes' or vent looking things punched in the inner layer (maybe into the cabin)?
    Perhaps moisture in the air is getting trapped in between the layers?

    The paint started to bubble and that's when i found the rust... I could understand if it was rusting out behind the seal but just on a plain piece of sheet metal i'm not so sure.

    I'm fixing it up but want to prevent it happening again?
    97 Disco 300Tdi, front & rear diff locked, hybrid turbo, full width intercooler, cranked front & rear arms,
    2” dobinson coils, terrafirma shocks, HD steering arms, diff guards, rocksliders, domin8r winch, tank guard

  2. #2
    Join Date
    May 2006
    Location
    Canberra
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    When trying to stop water leaking into my D1, I found the seam sealant in the gutters had failed, I poured fish oil in the gutter whilst the trim around rear side window was off, and in came in a lot of spots along joint also at the front behind the ECU (V8) I checked a couple of other cars, and they both had the same issue so I suspect most D1's may have this issue, as the top of the windscreen is at the same level this maybe where the water gets in, have you checked under the sound deadening stuff under the carpet in the front foot wells and near the back corner the water was sitting under there on mine even though the carpet seemed dry.

  3. #3
    Join Date
    Sep 2015
    Location
    In the shed or 1000km from home
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    Yep, i get the classic wet floors sometimes. I always thought it was leaking in via the inner front wings (or possible rusty inner wings) somehow - so the gutter sealant idea is interesting!
    I'm going to pull down the headliner and check out the edge of the inner roof sheet that runs along near the windscreen as well.
    Has anyone got the top roof edge that the windscreen sticks to replaced before - new one welded in?
    97 Disco 300Tdi, front & rear diff locked, hybrid turbo, full width intercooler, cranked front & rear arms,
    2” dobinson coils, terrafirma shocks, HD steering arms, diff guards, rocksliders, domin8r winch, tank guard

  4. #4
    Join Date
    Nov 2012
    Location
    Kingsley, Perth
    Posts
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    i repainted roof on mine. theres a thread somewhere. will fish it out for you. pulled windscreen out and had some rust but not too bad. i grinded it back and etched, filled and painted it black. then a pro windscreen fitter came and put windscreen back on for me and had new finishers to go with it. had been doing fine since. i know you can cut and well it too. mine didnt need it but ended up welding a bit of the alpine window back at the same time.

  5. #5
    Join Date
    Nov 2012
    Location
    Kingsley, Perth
    Posts
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    Factory roof rail removal, plugging holes

    not sure if it helps but hopefully does

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