<VV> Windshield Sealing

[Dale Dewald]

Hello All,

I was visiting the fellow doing the bodywork/painting on my wife's 65 Monza 
and we discussed ways to repair rust around the lower corners of the window 
frame and how to prepare/finish that area to avoid future rust.  The car is 
to be a driver (all weather, but not winter/salt), so modifications that 
would enhance durability might be preferred over maintaining stock 
appearance.  I will be installing a replacement windshield as the current 
one is cracked.

In any case we plan to weld in new metal to repair any perforations. The 
entire area will be ground to bare metal and treated with POR15 prior to 
finish painting.  However, the question remains how to deal with water 
drainage in this area. Should we:

1) Rebuild the area as stock, except perhaps enlarging the water drain hole,

2) Create some other drain path for water that flows into this area,

3) Completely fill/seal the channel between the body and glass?

If I choose option 3, I would install the glass as usual with butyl tape, 
then fill the remaining space with clear silicone caulk and install the 
trim, bedding it in the fresh caulk.  Additional beads of caulk on both 
sides of the trim would seal it to the body and glass.

Opinions are welcome, but does anyone have first hand experience and 
results of applying option 3?  Did it work out better than the stock drain 
system?

Dale Dewald
Hancock, MI