Toyota 100 Series – Front Windscreen

RE:     Toyota Landcruiser 100 Series –  Front Windscreen Aperture (Corrosion Repair)

This document has been prepared with photographic illustrations to highlight the severity of corrosion damage and the recourse of the repairs conducted.

1.0           Initial Inspection – 22/01/19

On the 22/01/19 @ 20:30pm, an assessment was carried out to determine the extent of vehicle damage and to enable an estimate for the repairs to be carried out at the clients residence. From the initial review, a preliminary rectification schedule was compiled and estimated (the basis of the repair scope and estimate was the use of lead filler and two metal plates to fill the large void areas). The photo below illustrates the conditions at which the assessment was carried out (at night and under insufficient lighting).


2.0           Vehicle Review – 24/01/19

The vehicle was delivered to the workshop on the 24/01/19 at 09:30am. The vehicle was reassessed under better lighting conditions and the following observations were noted. The photograph below illustrates one of the void areas where the level of corrosion damage was more significant with the corrosion penetrating through multiple layers of the windscreen aperture.


The second observation noted was that the outer turret skin had separated from the internal support frame. This is clearly visible by the horizontal fracture line of the full length of the windscreen aperture.


3.0           SCOPE OF WORK

From the condition review/reassessment conducted on Thursday 24/01/19, the following scope of work was conducted to meet the basic requirements of the repair and return the structural integrity to the panel section.

3.1                Turret Aperture

In light of the condition reassessment and scope requirements, a complete new panel section was fabricated to match the original profile. The fabricated panel was then trial fitted for the correct contour and alignment.


Note: the multi-layers of corrosion build up beneath the aperture were obstructing the correct alignment of the replacement panel, so the complete lower lip of the aperture was removed.


Upon removal of the windscreen aperture section, the internal support frame was found to be weakened by the corrosion. The area was sandblasted to remove the corrosion contaminants and clean the metal surface ready for welding.


The panel replacement section was aligned and held in position by clecos and then fully welded.


3.2                Vertical Apertures

Both of the vertical apertures were found to have localised areas of corrosion around the perimeter of the (pillar trim) fixing holes.


The full lengths of both apertures were sandblasted to remove all of the corrosion contaminants.

4.0           Conclusion


The remediation of the corroded turret section has been completed above the standard of the quoted repairs. The requirements have resulted in time/cost variations which we have absorb to preserve the integrity of our fixed price guarantee.

René Farrace

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