Window channels repair ideas.....

[Challenga]

I took out my front and rear windows.  I wire wheeled all of the rust and stuff out of there, but there are lots of pits and surface rust that is impossible to get.  I have two ideas that I want to run past you guys. Idea one is to put some kind of rust encapsulator on the channels and smooth them out with some filler.  Idea two is to paint on some POR15 then smooth them out with some filler.  What do you guys think?  I am really worried about the rust starting back up in those channels just because of the design the water sits in there.   

[Bullitt-]

I'd forget the filler, just gives moisture another way to get trapped...I saw on one of the TV shows using bronze brazing rod to fill in pits & small holes in otherwise solid metal after de-rusting. Then use a rust converter & sealer

[dutch]

blast & lead the area

[4 speed fish]

If you can get them good and clean I would use mar glass to smooth them out.

[E-Body Products]

Cut out and re-weld if possible.  We have tried both rust convertor and POR-15 after thinking we had cleaned all of the rust out of the pitted areas.  Went back into it after a couple of weeks and the rust was back.  Ended up cutting the pits out and replacing with nice clean metal.   

Brazing or Lead as mentioned above would work as well.