BMW 320i Restoration Project - Part 2 - Bring In The Subs

The next step was to bring in professionals to handle removal of the windshield and back window, and removing or improving dents.

Auto Glass Subcontractor

The rust areas around the windshield and rear window gaskets were right up to, and probably underneath, the window seals. So, it made more sense to remove the glass to tackle the rust issue from its origin underneath the seal. I enlisted the help of the trusted automotive glass installers from Auto Glass Specialists (AGS), who I have hired for glass installations and replacements for 25 years.

AGS sent out a technician to write up a cost estimate to remove and replace the existing glass, including whatever new gaskets were needed. Since removing front and back glass from an automobile comes with a moderate risk of cracking the glass during the removal, I asked AGS to include replacement glass with the estimate. I informed Rob of the potential for additional cost and he accepted that risk.

Under normal windshield replacement situations, cracking the old glass is not a concern because the replacement glass is already in hand before the removal begins. However, in the case of our vintage BMW, the staff at AGS was not able to locate a new windshield, even though a rear window was available. Nonetheless, I’ve previously had AGS perform removal and reinstall of the same windshield on similar projects without incident. Further, longtime AGS technician Jesse was confident. With Rob’s agreement, we moved forward.

Paintless Dent Removal (PDR) Subcontractor

My PDR specialist of choice is San Diego based Dent Medics, run by Jason Maguire, who I have known since meeting him when he was training in PDR in 2000. We’ve not only been great friends ever since, but have tag-teamed on hundreds of body panel repair jobs. We call it “push-to-paint” (PTP), a process in which he reshapes the dented panel as best as possible, and I come back with high-quality fillers, primer, and paint to make the panel look very close to original appearance and shape.

PTP costs a fraction of the traditional body shop approach of replacing everything. Plus, it takes far less time. Most customers prefer the cost savings and convenience, unless somebody else’s insurance company is paying for it!

I had Jason look at some photos and videos of three areas of concern:

• Dents around the right door handle
• Folded out left door edge
• Dents on the hood

Upon analysis of the photos, Jason concluded:

• The appearance of the right door could be improved (made less noticeable), although certainly not perfect
• The folded edge of the left door could be, as he humorously put it, “pounded into submission”, and,
• The hood dents could not be removed or improved.

Jason got to work and was successful in the areas with which he was tasked. 

The Window Surprise!

Meanwhile, Jesse from AGS successfully removed the windshield and rear glass without either one cracking. The gaskets were salvageable as well, although in need of heavy cleaning. The surprise was to find that those relatively tiny areas of rust popping up from under the gasket edges was just the tip of the iceberg.

Both front and rear window gasket tracks were heavily rusted. Jesse indicated that this was the result of this type of window mounting design that was common in that era. Water collects under the seal and just sits there.

Repairing this issue would require extensive work, including removing all the loose rust, grinding the remaining rust from the sheet metal, and sealing the remaining rust areas to reduce the possibility of them returning. This was much more work than I had originally included in Rob’s quote, so I sent the photos over to him, followed up with a call and a revised work order.

Fortunately, Rob understood the complexity of the situation and accepted the revision. My job just got significantly expanded!...

Stay tuned for Part 3. If you're looking to restore your ride or get your car detailed, contact Prentice at prentice@detailinprogress.com.