During your rust repairs, are you doing anything to the drain holes at the bottom of the front and back windscreens ?
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Because they have been a problem here in Australia.
It has been a very common problem.
Rust forms underneath and inside the panel. And you cannot just put windscreen sealant in there. That will hold in water and cause rust even more.
All older 504s here used to eventually develop rust holesat the bottom corners of the front windscreen and this weakens the pillars. Not good.
From my own experience, you can do 2 things :
1) Weld in some metal pipes to drain the water further away from where it usually goes. I used pieces of transmission pipe I found at the wreckers....they are steel and flared at one end. They were big because they came from a big car.
2) Renault 12s used to have no drain holes, but they did have a slot which the water could flow down, and then straight out the front......not inside. You could see it underneath the front windscreen rubber, but it was not very noticeable. Maybe you could create slots ?
I always thought this was a beter solution to the problem.
Either way, you really should squirt in some fish oil (or something similar) into the panel the water currently drains into.....there is always rust inside.
The back windscreen is the same, but not so bad.