I am going to repair a rusted out windshield channel and I am concerned that the grinding and welding will ruin everything under the dash. I would love to hear from someone who has done this without completely disassembling the interior, or starting a fire. ray: This repair would be on a 65 Skylark. I am thinking wet rags to stop the splatter???
I wouldn't even try that using a TIG. According to "Murphy's Law", there will be that one piece of spatter or spark that will find it's way into a harness or bury itself under the carpet up under the firewall. I know it is a major PIA but to be safe - remove or move everything out of the way. Wrap all the harnesses with heavy aluminum foil if you leave them. Remove the dash panel and the instrument panel. Peel the carpet and insulation back.
Just use pop-rivots and bondo! :bla: Seriously, if you are going to do the job, do it right. Remove everything you can and the tinfoil trick is a good one Have a fire extinguisher close, and a second set of eyes is always good!
Don't even risk it, I have seen several welding fires on cars before. The insullation under the carpet and firewall would be too close. Take the time and remove the interrior and bag it for storage while you do the repairs. You may wan't to consider the plastic defrost, A/C Duct work in the dash, ect., ect.. A car fire is very hard to put out.
I replaced the lower channel with a Chevelle repo piece on my 66. Basically did plug welds....drill a 3/8" hole in the top panel and weld the hole up to join it to the lower panel. All the welding is done from the top side. At the least remove the carpeting and firewall insulation. That stuff will catch a spark and smolder for quite some time before it erupts into flames.
Thanks guys, I kind of figured what you all said was what I would have to do....just didn't want to. Kurt
