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Some vehicles are prone to rusty window and door channels like 70's muscle cars, square-body or OBS trucks with their multitude of pockets, corners, and channels that love to hold water and moisture to create rusty problems. But the good news is that you can do some of that rust repair on your own.
Door frames: a complex system of curves, corners, and pockets – all of which love to hold as much moisture for as long as possible. You’ll not only want to stop the rusting process in those problem areas but seal the metal, too.
Window channels: These channels are runways that trap water between the glass and aging, dried-out rubber. And they do a great job of hiding the resulting rust until it is too late to prevent damage.
Roofs and rockers: the top and bottom of your car or truck can take a lot of beating from the elements. Small and medium-sized holes in your roof or rocker panels, created by rust, are problems you can solve with these products.
We’ve combined our most popular rust repair and prevention kit and utility products into one easy-to-use bundle, designed to attack the common rust problems.
The clear-cut process allows for the proper cleaning, prepping, and coating that creates a non-porous surface that seals and protects metal from water, fuels, acids, chemicals, salt, and other corrosive contaminants.
Step 1 - Clean it!: POR-15 Cleaner Degreaser (Formerly Marine Clean) removes grease, oil, dirt, and grime in one application without leaving residues, noxious fumes, or flammable solvents.
Step 2 - Prep it!: POR-15 Metal Prep (Formerly PREP & READY) provides the best adhesion for POR-15 Rust Preventive Coating on metal surfaces, including shiny polished metal surfaces.
Step 3 - Coat it!: POR-15 Rust Preventive Coating is a high-tech, high-performance rust preventive coating designed for application directly on stable rust or seasoned metal surfaces. Provides permanent rust protection with a hammer-tough finish resistant to acids, alkalis, and repels all fuels and oils.
This moldable metal putty filler is so strong you can drill and tap it yet gentle enough that you can apply it with your fingers.
You can simply wet your fingers, and work with it until it is almost perfectly smooth before it dries - eliminating most sanding! When it cures, it's Rock Hard, making it perfect for repairing steel, plastics, concrete, etc. Epoxy putty even sticks to damp surfaces, and will cure Underwater, so it can be used to fix leaking basement walls, swimming pools, plumbing fixtures, and so much more. Put some POR-15 Epoxy Putty In your toolbox today. You'll find yourself using it all over your shop and home.
Fix that seam or channel with POR-15 Patch. POR-15 Patch is quite literally POR-15 Rust Preventive Coating in a tube, and it dries as hard as a rock, remains flexible, and once dry is totally impervious to fuels and solvents. This rust hole filler is so tough it may actually add strength to weakened metal, and it won’t absorb moisture and swell like conventional body fillers.
WARNING: Cancer - www.P65Warnings.ca.gov.
Example Project: Repair rusted windshield channel after removing windshield for replacement
Remove windshield and rubber weatherstrip
Remove as much of the old coating and adhesive as possible from the area
Sand and wire brush the rusted areas removing any loose rust
Mix Cleaner Degreaser with one or two parts of water and apply to the entire windshield channel scrubbing it in with a small brush then rinsing off with water or using a clean wet sponge and clean towel.
When dry apply Metal Prep to the area and keep it wet on the surface for 20 – 30 minutes. Rinse or use a clean wet sponge and clean towel several time to be sure you have removed all of the Metal Prep. As the water dries the bare metal areas will flash rust and when completely dry a small amount of white powder will remain of the surface. This if completely normal and the correct surface for the POR-15 Rust Preventive Coating.
If the area is just rusted and no rust holes require repair the first coat of POR-15 can be applied. Once the surface is completely dry brush on the first coat of POR-15 Rust Preventive Coating. A second coat can be applied when the first coat has just dried and still has a slight finger drag or has completely dried and has been sanded. Epoxy putty can be mixed and applied to any pitted areas when the POR-15 still has a slight finger drag or has completely dried and been sanded. The pitted areas may require a wire brush the scratch into the pits for the putty to adhere correctly. Once the Epoxy Putty has been sanded and the repair complete you can apply a final coat of POR-15 over the putty if you choose.
If rusted holes require repair, I would suggest using a small piece of our Power Mesh, a thin fiberglass mesh, and place it into the wet POR-15 as you would repair a bicycle inner tube. Using the tip of the brush smooth out the mesh and any air bubbles that may be trapped under the mesh. Add a second layer if necessary. If you have access to the back of the area, I would add either a layer of mesh or our POR Patch to the area for additional strength and protection. Be careful not to make the repair to thick so you will have trouble fitting the new windshield rubber gasket into the channel. Once everything is completely dry sand the repair smooth and your ready to install the windshield.
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