Metal cracked under windscreen.

[Waspy]

So I have this crack in the corner under my windscreen (See image). This picture is actually before a repair I did on it. I grinded it back and treated the rust, at which point the crack only looked cosmetic, so I filled it and resprayed it. And it looked great. Seem less even. However after jacking the car up, the crack has reappeared through the filler and paint which raises structural concerns with me.

Is this a common area? Is it weld-able? Anything I should know?

[Wayne]

That will need the screen removing and then the cracked section cut out and replaced.

But I suspect you have deeper problems with the shell flexing

[Waspy]

Screen need replacing anyway since it has a nice arc scratch after the wiper disembarked at 80 on a rainy day 

In my head that doesn't sit right. It doesn't feel like the kind of area which can just be cut out... But I'm no expert.

Getting very tempted just to buy a better Gti..

[Mr Blue]

That crack isn't normal. Has the shell been in a stunt? Check behind the wings for rot around the a pillar while your there

[Waspy]

Has the shell been in a stunt?

I always wanted a stunt car! But not that I know of.

So maybe this car is just a challenge... Yeah. Let's call it that

[Thom89]

Metal fatigue caused by the front of the shell flexing, I'd like to bet that the "A' posts have rot well set in around the area on the inner wing side of where the bonnet hinge mounts. The crack is slowly working its way around the screen pillar at its weakest point! Recognising the problem, and correct rectification are crucial at this point! Removing the wings for inspection of this area is about the only way to find out for sure!

Also worth inspecting is the area at the base of "A" post, where it meets the floor and sill area, and ramp lift bobbins on the underside of the floor pan, if this part of the car is rotten, then all stress will go to the cracked area!!

Edit, just re read your OP, seems you've answered your own question!

"However after jacking the car up, the crack has reappeared through the filler and paint which raises structural concerns with me"

Thom

[Waspy]

Recognising the problem, and correct rectification are crucial at this point!

What is correct rectification?!

*Goes to start project thread*

Thanks for the reply Thom. Supposing the A pillar is nice and rotten. Is it game over? How do you even go about repairing that?

[roberto]

you need to get the wing off first then all will be revealed. I certainly wouldn't condemn it yet. its amazing how much body shells flex without you realising. off course they shouldn't flex in that area enough to crack a small bit of filler.