1939 Pickup windshield frame repair

[kehughes]

Anyone ever repair these? One of the inserts that connects the 2 halves of my windshield frame is broken and the other is pretty rough with a broken screw still in it.
I was thinking I could replace them with 5/16" square steel....if I can get these out. These are stuck.
Are they just inserted a few inches in this side also? Any recommendations of how to remove?

[SofaKing]

For the broken screws, I just redrilled and re-tapped the hole but I didn't have 4 of them. For the broken insert I would try penetrant, PB Blaster, or personal fav, heat and working it loose taking care not to bend the frame too much. If that failed a last resort might be to drill it down the center and pick out the corners. Then there is also a thing called a rescue-bit which is like a rotary file but will remove hardened steel like ez-outs. Same idea, grind out the majority and pick out the rest.

[V12Bill]

I had to replace the inserts in my 1939 PU when I rebuilt it. The size is 5/16 " square, but square stock comes in 1/4" and 3/8". I had to have 3/8" milled down to 5/16" . The insert inserts the same length in both pieces. There is a slight bend in the insert at the joint. Follow #2 advice on removing the old inserts. All in all, it is not a difficult job.

[37 truck]

You can buy 5/16 key way, and it works just fine.

[kehughes]

What do you guys think about drilling a hole in the bend of the frame in line with the insert and using a long punch to knock it out? Then weld the hole back up or would I even have to?

[SofaKing]

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Originally Posted by kehughes

What do you guys think about drilling a hole in the bend of the frame in line with the insert and using a long punch to knock it out? Then weld the hole back up or would I even have to?

I think that is a very interesting idea. My concern is that the hammering will bend the frame unless you firmly support the shape and contour. Careful rewelding, (or drilling) the seal slips into a groove and any blockage of that groove will prevent the seal from slipping to place.

[35ragtop]

I had to drill mine out (38) like Sofaking said, they just refused to budge even after soaking for days in one of the rust removal solutions. I was concerned about damaging the frame if I hit it with a hammer. Made up some new squares out of 3/8 mild steel, filed to suit. Tapped new holes and fitted with stainless screws. Also when I assembled it I used a never- seize compound on the mild steel. Should see me out!

[37 truck]

I would drill a hole in the broken square piece, tap it to say 10/24 and use a slide hammer to remove it.

[mrtexas]

I'd try rust911 or evaporust and then heat.