Roof Rust Opinions - Please

[The70RT]

I am to the point of welding in a new rear upper window channel I got from auto body specialties. I know I have to cut all that out like I did the bottom. I have surface rust further onto the roof though and it looks like some of it is like maybe 50% thru but no holes. Where is the point where I should cut out and patch? I have been using some Inmont R-M 801 metal conditioner and has been disolving the rust pretty good. I have an area where I almost got all the rust removed when wire brushing it with the conditioner. I was thinking on the worst pits (50% through) maybe just filling it with the mig and not cutting any out unless it is the last resort. Or can I apply something over it like all metal or metal to metal? Here are some pics. Any advice would be greatly appreciated. Thanks guys

[The70RT]

     LEON?............1HOT68?.......anyone?

[1BAD68]

I've never tackled a roof but I'm thinking what I might do here is grind out all the rust even if you create bigger holes making sure that ALL rust is gone. Then coat it with a rust inhibitor and then fiberglass it with mesh. The fiberglass will give you a solid surface to work with, I would go with two layers and then skim coat with filler, sand and prime. Unless of coarse this is a #'s matching V code or HEMI project.

[tan top]

if it were me before i cut any thing , the roof skin needs to be blasted or something  , because that rot looks pretty deep . you may even find that after blasting there is hundreds of pin holes where the rust was so deep & the good metal was too thin , depending on how bad part of the roof skin might need replacing also.

[hutch]

Please do not do what I am going to do as I am not a pro, I just want my car to look nice rolling down the road.  I too have this same amount of rust on my roof and i was just going to sand it down as far as i could then hit it with some rust converter and build up the spots with primer and filler.  Kind of like what I would do with drywall.     I think I can get the finish looking smooth and consistant.    Is this not an option? will the rust come back?  Rust needs air to live I always thought.

[Charger-Bodie]

the first thing i would do is wire wheel the pits so they are really clean if they are not deep i would have no problem with spending a bunch of time slowly zapping each one with weld .....just go slow as not to warp it ......by the way is it going to be vinyl ?

[The70RT]

the first thing i would do is wire wheel the pits so they are really clean if they are not deep i would have no problem with spending a bunch of time slowly zapping each one with weld .....just go slow as not to warp it ......by the way is it going to be vinyl ?

Thanks. Thats what I was hoping someone would say but needed opinions. Yes a vinyl is going back on. I am gonna put the lip in and take an inch out towards the roof where it is bad for sure. I don't think I am gonna run into any holes past that since I wire wheeled that shiny part further up in the pic where was worse and still didn't go through.

[tan top]

the first thing i would do is wire wheel the pits so they are really clean if they are not deep i would have no problem with spending a bunch of time slowly zapping each one with weld .....just go slow as not to warp it ......by the way is it going to be vinyl ?

      i had to do the same also in a few spots , as after i spot blasted the areas it left tiny pin holes ,wire brush / weld them up.

[K9COP]

Mine is much worse than this, but i'd consider chasing one of the ebay parts car buyers and seeing if they chop a section of the roof for you. I know nothing about welding or bodywork, but won't lots of welds to fill the holes warp it?

God I'm hopeless with bodywork. good job I'm half decent at my job or I'd hungry.

[The70RT]

Mine is much worse than this, but i'd consider chasing one of the ebay parts car buyers and seeing if they chop a section of the roof for you. I know nothing about welding or bodywork, but won't lots of welds to fill the holes warp it?

God I'm hopeless with bodywork. good job I'm half decent at my job or I'd hungry.

Yeah i seen your thread......wow! ....worst i seen. No mine isn't that bad I have a little experience at welding and body work. I put my trunk,rear valance,ends and a quarter on. I got the upper channel but it isn't gonna fit for crp. I hope to not cut much out . Pics kind of look worse than they are. IOn the pits I have to just go slow and move around so I don't do any warping.

[K9COP]

good luck buddy. Fancy a free week in the cayman islands welding my roof and floors in?

[The70RT]

If i could .......i would be rich. I started on it 5 months ago............and many more to go. It will be worth it 

[hemi-hampton]

70RT, I would blast with little had held blaster. This will get down in the pits where a wire wheel may not. If you weld keep heat low as thin metal will blow a hole threw it fast & easy if to hot & then your chasing a big hole & then a mess. After a few welds blowoff welds with airgun to cool & minimize warpage, then continue.  Then grind welds, thin coat of Plastic filler, Then Epoxy Prime. Some prefer epoxy prime then plastic filler. If worried about heat & warpage from welding & grinding then Plastic fill then epoxy prime. Many different ways to do it. LEON.

[The70RT]

70RT, I would blast with little had held blaster. This will get down in the pits where a wire wheel may not. If you weld keep heat low as thin metal will blow a hole threw it fast & easy if to hot & then your chasing a big hole & then a mess. After a few welds blowoff welds with airgun to cool & minimize warpage, then continue.  Then grind welds, thin coat of Plastic filler, Then Epoxy Prime. Some prefer epoxy prime then plastic filler. If worried about heat & warpage from welding & grinding then Plastic fill then epoxy prime. Many different ways to do it. LEON.

Thanks again Leon.