You might be lucky and it is just surface rust, but if you can poke a screwdriver through it I'm afraid it has rusted from the inside out.
You'll have to pull the headliner and have a look in the cavity to be sure.
Best of luck!
Printable View
Got a bit more done...
Clamped up the rear gutter section:
Attachment 83038
Plug welded it in:
Attachment 83039
Started on the first side piece...
Apply a bunch of clamps:
Attachment 83040
Realise that due to sitting on your lawn for about a year, along with having bits chopped out and more bits welded in, the roof is not exactly the right shape, so persuade it with a strap:
Attachment 83041
Apply many tacks:
Attachment 83042
Spend a few hours stitch welding the whole lot (going slowly to minimise warping)
Attachment 83043
Grind it all flush:
Attachment 83044
Throw on some etch primer:
Attachment 83045
Now I have to repeat that process until there is a new band of steel around the whole roof, fabricate the corner pieces, then plug weld the whole lot to the gutters and braze the corners.
Bloody awesome work mate can't wait to see how she comes up [emoji106][emoji106]
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@Nhoward how you going with this mate? So looking forwrd to seeing you finish this. So impressive.
Bloody hell I just went right through this thread . Incredible 👍🏻
Unfortunately I have been rather busy with work/life in general so progress has been a bit slow (and there is a subdivision going in next door, with construction 6 days a week, so I am trying to not piss off the neighbors with my own power tools)
I have managed to get a bit more done though.
I have not taken as many photos this time, as it's the same procedure I used on the other side in the last post.
Setting up the left side for welding (with added strap persuasion and a ton of clamps):
Attachment 83647
Attachment 83648
After that came the usual deal - tack it in a bazillion places while shoving it this way and that to get the bits in alignment, then weld it all up:
Attachment 83649
Did the same thing on the back:
Attachment 83650
Also added some er... substantial... reinforcement to the long-suffering bunnings tent keeping the rain of the project as it was trying to take flight:
Attachment 83651
Next step will be to fabricate the 4 corner pieces, then roof attachment time!
Well... MudRunnerTD called it - the tent got trashed.
A couple of months ago we had the worst storm of the year, and at about 4am the top of the tent took off into the night. I was up to my eyeballs in my day job, so I let the patrol sit under the tarp for a while. Shortly after that, delta hit our shores and it was back into lock down we went. What fun.
What was there before:
Attachment 84373
What resulted after:
Attachment 84372
Fortunately the tent had started leaking, so I was in the habit of keeping the patrol under a tarp inside the tent.
Right then... If I want to progress this thing I need some shelter since the weather is still garbage.
Fortunately I'm known amongst my friends as that guy that hoards random useful crap (I often get calls along the lines of "hey we are about to throw out <random stuff> do you want it?) end result - I had some timber laying around.
I added "vaguely sufficient carpentry" to my list of random skills and constructed this lot:
Attachment 84379
Attachment 84380
Excellent... somewhere dry to work, and with a much lower chance of it blowing away in the night.
Attachment 84371
Right... now that I have somewhere dry to work, back to the patrol.
Fabricated what was the most irritating piece of metal in the whole project and started persuading it in to place:
Attachment 84374
Welded it in:
Attachment 84375
Fabricated the bit for the back right corner, then stuck that in:
Attachment 84376
...and ground it back:
Attachment 84377
Similar deal with the front left:
Attachment 84378
Next up:
- Finish fabricating the piece for the back left corner
- Finish fabricating one tiny bit for the front right corner
- Pull the roof off again, clean up any of the welds that need it
- Prepare the corners with flux for brazing
- Final roof fit-up and far, far, far too many plug welds!
Far out mate, you have to be the clear leader for best first 25 posts in the history of this forum. Just love what you've done so far.
Yeah wow Kudos to a job done well, bloody amazing can't wait to see hire she comes up [emoji106][emoji106]
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