Some time ago the same problem was subject of a discussion between me and Wijnanda van der Sman

Below are the steps she have taken to stop this problem.

Step 1:
I have the fabric upholstery cut away just above the windshield rubber, under the chrome trim of the upper windscreen I removed the rubber rubber and then cut the outer covering on the seam with the inner lining.The chrome trim stripped above the windshield on the sides and covered with protective tape during work The chrome tees on the side of the windshield are removed to be able to work well in the corners of the front frame and keep the water drainage in the holes .Consequences:· The rubber rubber needs to be secured / glued again· You can no longer reuse the original fabric from the outer covering

Step 2:
Destroy the affected metal parts with RustyCo. This certainly done 3 times and intermediate sanding, sanding, sanding, sandingThe front frame is, as it were, a hollow flat tube with a few nice curves. In particular, the beautiful rounded corners of my car just rusted away. I also cleaned this hollow space as well as possible from all loose metal particles and rust formation. So I did not make the choice to let this part shine (too thin metal) or to have it welded.Consequences:· Because of the sanding you can quickly reach the chrome trim on the windshield. Cover this well / cover· This process takes at least a day or 2 to give the RustyCo a good time to do its work and to clean up in the meantime

Step 3:
I have also done the “build-up” myself by first smoothing the largest holes with fiber mat and auto-lamination / resin and then making new rounds at the corners with malleable metal, so that I have the original shape back. I had already seen a kind of mallet in step 1 before I started sanding and removing loose parts.Consequences:· This process also had to be done in steps because the filler / resin needs to be properly cured for the next layer· When recalibrating the curves, take into account the water drainage on the side of the windscreen. Above the doorposts there is a gutter with the side of the wheat panels “in”. This gutter takes the (rain) water both to the rear and the front. If you remove the decorative strip and the T-strips on the sides of your windshield, this gutter can be clearly seen. When re-building the corners, this outlet must absolutely return so that the water can keep running away.

Step 4:
I also did the finishing work myself. Only with fabric upholstery but with a new product, namely PlastiDip. This is liquid rubber in an aerosol can. First spray a special primer and then the plastidip over it. In total I had to spray 1x primer and then 3 thin layers of black colored plastidip. I have all the parts where the outer covering was covered with plastidip, so also the gutters above the doors and the edges around the wheat rubber.

Consequences:·
PlastiDip gives a layer that protects against moisture and looks good (temporarily).· PlastiDip forms entirely to the bottom layer and is very easy to remove later when the “re-coating” project is started by an official company.· When spraying with the primer and plastidip ALL parts where you do not want rubber on have to be covered (the same as if you would spray the car with paint)· I sprayed the primer and plastidip standing in the car in the openings of the targa panels and worked all around, making a whole stroke for 1 layerMaybe you’re wondering why I did not immediately choose to take out the windshield and have the frame trimmed again. At that time, it was a question of uncertainty whether my XJ-SC would endure the test of “shelf life”. I restore the car in stages and share it in manageable “chunks”. The outside was planned for me last, first the loadbearing parts (subframes front and rear) and motorically in order and then the sheet metal and the niceness. However, due to leakage at the rusted parts of this front frame, I have executed this temporary solution until the moment the targa panels are re-coated and the new rubber rubber is put in and the new rear roof. For this all parts already in house.I want to have this job done by a company in Elst that specializes in convertible roofs and repairs.

I have in pdf some pictures. If anyone of you like to have those just let me know your email.

Regards, Eltjo Ottjes

XJ-SC V12 1986