Suzuki Samurai -Windshield Frame Rust Repair 2 of 2

Suzuki Samurai -Windshield Frame Rust Repair 2 of 2. This was a quick repair on some minor rust-through holes in the windshield frame on a Suzuki Samurai. Jeeps, CJ5's, CJ7's and Wranglers would benefit from this fast repair that will stop the rust completely. I ground out the area, then coated the inside of the windshield frame with Chassis Saver (which will lock it and stop any future rust). Then I made some small patch panels out of sheet metal and bonded them in with 3M panel adhesive. (part no. 08115). 3M panel adhesive (part no. 08115) is made for bonding on quarter-panels, and door skins and other non-structural body parts. In recent years most cars have their panel bonded on at the factory versus welded. The bid advantage of using panel adhesive is that the back of the panel can be totally rust-proofed. When you weld, even when using weld-through primer, there is always some area that is exposed metal and can start to rust through again from the inside. that is not the case with panel adhesive. If you want a flat, clean job, the best way would be to flange the metal so the replacement patch panel would sit in the hole flush. But I am just going to paint half this Suzuki Samurai with spray truck bed liner in the areas that get subjected to the most rocks and debris. It's not worth putting expensive paint on an off-road vehicle in my opinion. It will be all black with half gloss black and the other half flat black truck bed liner.

Suzuki Samurai SJ413 JA51 Fender Repair & Bodywork 4 of

More rust killing of the 1985 Suzuki Samurai Jimny 1300 SJ413 JA51 (not sure what it is - probably a Japanese Jimny 1300 JA51). I am using 3M body panel adhesive to glue on a new patch panel and also to fix very minor rust pinholes on the front valance. The 3M panel adhesive is not like Bondo at all and 3M panel adhesive is totally impervious to water. Most new cars today have quarter-panels and rocker panels glued on with panel adhesive versus the old method of welding. So the panel adhesive is almost as good as welding but is also much less prone to rusting at the seam or joint. For some fast but good prep work I used compressed air to clean the surfaces, then some light sand-blasting and more compressed air. Then I followed that up with brake-clean and then compressed air. You do want to leave some rust when using the Chassis Saver because it grips a lot better. If you prep the area a lot and make it too smooth, the Chassis Saver could fail. So actually if you do less work the Chassis Saver will grip better on clean rust. These Suzuki Samurai Jimny 1300 SJ413 JA51 often have rust by the battery tray. Even though this Jeep was maintained, dirt and leaves will accumulate in the battery tray area and cause a rust out. The solution is to clean it out and use Chassis Saver. And then I made a heavy duty 12 gauge plate for the battery tray. I will be using an over-sized Group Size 75 side-terminal battery in the Suzuki Samurai Jimny 1300 SJ413 JA51. I am using the post adapters for the side terminal battery. To stop the problem of chips in the paint from off-road use, I will use truck bed liner on the front valance, the front edge of the hood and around the wheel wells and the bottom of the fender and the bottom rear of the quarterpanel and tailgate. These areas get lots of rocks, dirt, stones and mud throw up and that is where paint will chip and rust will start. Most of this Suzuki Samurai Jimny 1300 SJ413 JA51 will be painted gloss black. I plan to use Dupont Nason which is fine for a Jeep if you get a good price of $99 for a gallon with the catalyst and reducer.