Upon closer inspection of our chassis, to our dismay, we found that a poorly replaced front windshield had allowed water to accumulate under it, trapping it and allowing the cowl to rust through, thereby allowing water to enter the car and rust out the front ring module in one place.
After cutting out the rusted areas, Zack made patches out of sheet steel and bent them to match the contours of the original metal. This area had two layers so he patched the inner layer first then welded a second layer over it. This is the inner layer patach. Zach applied zinc weld through primer on these parts to protect them from the inside after they were welded from the outside.
This is another view of the inner layer patch.
Next, Zach welded the outer layer. So instead of just fixing the rust hole, Zach restored the structure of this important part of the unibody.
The completed repair has plug welds joining the inner and outer layers, making the repair stronger than OEM.
