Windshield base rust

Porsche dealership found this when replacing the windshield. The estimated cost for a proper repair, which involves cutting stuff out and welding, is $13,000. To slow it down by scraping it off and applying a rust inhibitor, the estimate is about $1,500. I'm likely going to go the latter route, but wondering if someone else has dealt with this? I'll be keeping this car for a long time so would like to do this right.

I have no experience with this stuff so my opinion is only worth what you paid for it. But it looks like only a small perforation of rust. Most is just surface rust. So not structural. IMO no way it is worth the $13K cost. I'd take it to a good quality body shop and get another quote. The main goal is to prevent further deterioration - not make it like it was factory new. Once the windshield is replaced, it won't matter as long as water intrusion is stopped.

Thank you, it is a relief to hear this. I am having it scraped out and inhibited, but was worried about that choice.

Same issue on a 2006 Boxster . Had the windshield replaced through insurance and while the windshield folks were at it, a body shop scraped it down and repainted for $600.

I wonder in these cases if this was a factory error, or caused by a prior windshield replacement. They use a wire to cut through the adhesive that holds the windshield in, and if done correctly (with pully's glued on the old windshield) the wire never comes near the metal, it rides along the glass edge. BUT - I've also seen shops remove a windshield by poking a wire through the sealant, then putting dowels on each end of the wire to use as handles - and basically saw it around the windshield to cut the sealant/adhesive. The reason I suggest that is many years ago I had a windshield replaced - and that technique with the dowels was used, and it resulted in scraped paint about where you're seeing rust. Luckily I noticed the bare metal and had it treated and painted while my rusted fenders were being replaced (Volvo Amazon Wagon.. very cool car..)

This is a chronic Porsche issue. It seems to be getting better with recent models, or maybe they just haven't been around long enough for it to surface. I've seen it in a car that we know for sure never had the windshield out. A good body shop with a lot of Porsche experience can sort this out so it stays sorted for a long time. Cost should be below $2K, and that's for the SF Bay area. Your costs might be (should be) significantly lower.

The pinhole does look kind of bad but no way should that be anywhere near $13,000 I think you should do it yourself. It would take some time masking it all after you sanded and sprayed with primer and top coat etc. that being said if you don’t want to do it, $1500 including windshield replacement sounds like a pretty good deal

Turns out there's a TSB for this for the 930s: Dropbox .

They are scraping it off and putting in some rust inhibitor now. I will inspect it on my next windshield change, I'm glad I at least know it's there.

Thanks, love your videos!

To close this thread: Porsche contracted the rust removal and inhibition out to a bodyshop, which cost me about $1,500 in total (including respraying part of the paint next to the windshield that had bubbled). It was indeed surface rust that was treatable, glad I caught this in time! I've seen 993 restoration threads of owners discovering rust below their windshield, so keep an eye out on yours too.

The $13,000 repair is the proper long-term fix, cutting out and welding the rusted sections. The $1,500 rust inhibitor option is only temporary and the rust will likely return. For long-term ownership and structural safety, the full repair is the best choice; the cheaper method can buy time but isn’t permanent.