Inner window frame repair

The inner window frame is a mess, but I refuse to buy a new one.  I want to restore this thing, and a repopped part (not my term) from an aftermarket supplier just feels wrong to me.

These are the tools I need to get going.  A new attachment for the grinder (tasty) and some Permatex Rust Treatment, which I'm going through like bottled water.

 This is the top rail, in the center.  It's knackered but not dead yet.

The rest of the inner window frame is morbid, at best, but I'm determined to make it work through a combination of rust treatment, grinding, fiberglass resin, and patch panels.

The only reason I feel like I can save this rot is because it ultimately isn't structure.  Yes, it holds the glass in place, but it doesn't hold my kids or the gas tank in place, so ...

Clamped in place so that I can go at it with the new grinder attachment.

Much cleaner now.  And that little bit of rot means even less to me.

While I was at it, I decided to strip the entire frame down to bare metal.  I needed to know if there were any pin holes that needed attention.

This is one bulge I can't seem to make go away.  The rust is just too much right now.  I might use a cutoff wheel and slide a chunk or two out of it, squeeze it together with a clamp, and then weld it back up. We'll see.

For now, I need the rust converted so that whatever I do end up doing will work.

I tilted the frame parts up over a bucket so that the excess Permatex could drain out.

I'd left this hold in the main window frame so that I could pour Permatex inside the frame to stop any interior/unseen rot.

I then covered up all the holes I could find with some painter's tape.  These are for the lower cowl seal.

This is a hole of my own drilling.  It got me access to the lower cross bar, which had some dust inside it that I could hear rattling around.  The middle cross bar had the same and got the same treatment.  Now when I shake it, no noise, thus no loose rust.  Job done.