Rust in windshield top pillar...
 

I have rust in the pillar and along a significant portion of the header. Has anyone ever repaired this? If so, how?

Thanks because there is no way I can ensure that I have no leaks without correcting this problem...

I have the same problem. It is not real bad, but still not something I want to see. A body shop told me that my car was probably rolled at some point and not repaired very well :(.

header rust...
 

I am going to take the windshield out again and I have found a welder that works with the shop that will rebuild the affected area with new material.

I am going to be charged about $100 for the welding, and $60 for the windshield re-install by a professional.

I will take pics of the affected area today...

Don't really have to remove the windshield. This is typical on the 79-93 stang. This is the place where the roof join the pillar. When the car get age. This place begin to rust Specially on V8 mustang.

On mine, i just had to remove the trim and the body shop done a good welding job without removing the windshield. Anyway you can crack it when you remove it which it could be the same result as let it there. Just have to take care.

Try to find a place you can trust for welding.

My 0.02$