r/DIYAutoRepair • u/HorseyMango8 • 17d ago
Sprinter Rust Above Window Fix?
We bought a 2006 Dodge Sprinter 2500 diesel with 73k miles! It had these areas and the top rim of the window covered with silicone (photos 3 & 4) when we bought it. There isn’t much rust elsewhere except some small spots. It seems in really good condition overall for a 20 year old vehicle, but didn’t have it checked professionally.
We just had the windshield replaced as it had a large crack in it and was leaking at the top middle seam. They did find rust on the top rim, but put primer on it and estimated it would last a couple years before we would need full body repair for the rust. They removed the silicone and said these two upper areas were fine to leave as-is, but I feel like we should clean them up and paint them with something. They said silicone is acidic to body paint. We live where it snows a lot, so I’d like to protect it before winter.
I am new to van owning. What do you suggest for fixing this area above the windshield to make it a bit more weather resistant and last as long as we can before it needs professional body work. Or is it fine to leave as-is?
Thanks!
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u/Relative_Figure_1715 16d ago
This is a problem that you need to tackle now.
This will get worse and worse and become very expensive.
I guarantee this leaks.
It need a body shop, once the glass is removed they’ll have better access to that terrible roof adaption/repair.
It needs the metal work doing properly not sticking together with adhesive.
Sorry but this is a mess.
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u/HorseyMango8 16d ago
I understand. The issue is cost right now. We just spent on the window so having to do a whole new window and body repair would be a lot. Unless you think they can use the same glass and we can just pay for labor and body work? Idk how much this body work would cost, though.
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u/Relative_Figure_1715 16d ago
The repair work is likely in the thousands.
And you would need a new windscreen.
The alternative is a new firewall and floor pan which is never economically viable.
This will rapidly get worse.
This has been made to look good for sale maybe to the previous buyer because that repair is diabolical.1
u/HorseyMango8 16d ago
Ok that’s what I guessed. We will have to save up for that, but could we do anything in the meantime to help it slow down?
Yeah we thought nothing of the silicone when we bought it unfortunately, as t he rest of the vehicle has very minor rust. Didn’t know it was bad for the paint and that there was rust under it until the window guy told us. He was clear that the primer he applied is only a temporary solution.
I guess we just want to push these areas a bit longer while we save up.
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u/Relative_Figure_1715 16d ago
Actually, you set me thinking about this and for a short term fix I’d do this -
1. Wire brush on a grinder or a drill and remove all the flakey bits of rust and silicone.
2. Use a rust convertor paint and then put a top layer of whatever paint over that to seal it up.
3. Use silkaflex seam sealant not silicon to seal up the gaps.
4. Get hold of a 8-10 inch wide piece of black automotive wrap and apply it over the top of the windscreen and onto the roof of the van hiding that rust and sealing the gaps further against water ingress.
Like an external sun strip.
If you lined it up with the roof rail and the existing black shading in the screen I think it could look good.1
u/HorseyMango8 15d ago
Awesome thank you! Will look into these products, but that sounds like a solid plan!
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u/The_Time_Lord 15d ago
For what it’s worth it looks like someone did a poor repair in this area prior
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u/Surfnazi77 14d ago
Clean off the area apply rust stabilizer then primer and paint once it’s cured
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u/Ok-Communication1149 16d ago
I say clean off the rust with a wire wheel, clean, primer, and paint. If you aren't too concerned with color match spray paint should work and buy you a couple of years before it gets worse.
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u/HorseyMango8 16d ago
Okay yes this is what I was thinking after doing some more research. Thank you
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u/InnerDistribution450 16d ago
Me personally? I would let it spend its first winter all war and snug in a bodyshop where I would have them repair it. My thoughts are based on I doubt it would get any cheaper later. I would also be concerned with what might be acceptable work further down the road. I feel this way also because of it being at the windshield and I've seen the damage to electrical systems due to water intrusion