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Thread: Old patrol roof rust repairs

  1. #41
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    Quote Originally Posted by Intrinsic View Post
    I just bought a 1980 MQ that has what appears to be a couple small rust sections in the roof at the gutter line (as well as the door corners but that should be easy). I was thinking an easy fix, but after seeing what happened to this one I am dreeding to see what lurks behind. I can only hope that it is not as bad as that
    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!

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  3. #42
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    Quick update...

    Got a bit more done...

    Clamped up the rear gutter section:
    fitup-rear-gutter.jpg

    Plug welded it in:
    rear-gutter-welded.jpg

    Started on the first side piece...
    Apply a bunch of clamps:
    all-the-clamps.jpg

    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:
    strap-persuasion.jpg

    Apply many tacks:
    tackathon.jpg

    Spend a few hours stitch welding the whole lot (going slowly to minimise warping)
    seam-welded.jpg

    Grind it all flush:
    grindback.jpg

    Throw on some etch primer:
    etchprime.jpg

    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.

  4. The Following 6 Users Say Thank You to Nhoward For This Useful Post:

    Avo (28th March 2021), Cremulator (17th May 2021), MB (25th March 2021), Plasnart (25th March 2021), Rossco (25th March 2021), Touses (26th March 2021)

  5. #43
    Legendary Rossco's Avatar
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    Bloody awesome work mate can't wait to see how she comes up

    Sent from my SM-G930F using Tapatalk

  6. #44
    Breadmaker Shaker Plasnart's Avatar
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    @Nhoward how you going with this mate? So looking forwrd to seeing you finish this. So impressive.

  7. #45
    Patrol Guru Sprock's Avatar
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    Bloody hell I just went right through this thread . Incredible 👍🏻

  8. #46
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    Bit of an update

    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):
    leftside-setup.jpg
    leftside-clamped.jpg

    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:
    leftside-welded.jpg

    Did the same thing on the back:
    rear-roof.jpg

    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:
    reinforced-tent.jpg

    Next step will be to fabricate the 4 corner pieces, then roof attachment time!

  9. The Following 8 Users Say Thank You to Nhoward For This Useful Post:

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  10. #47
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    Still here and still at it...

    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:
    before.PNG

    What resulted after:
    after.PNG

    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:
    construct-tent-1.jpg
    construct-tent-2.jpg

    Excellent... somewhere dry to work, and with a much lower chance of it blowing away in the night.
    inside-the-tent.jpg

    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:
    part-from-hell-fitup.jpg

    Welded it in:
    part-from-hell.jpg

    Fabricated the bit for the back right corner, then stuck that in:
    corner-welding.jpg

    ...and ground it back:
    corner-groundback.jpg

    Similar deal with the front left:
    FL-welded-groundback.jpg

    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!

  11. The Following 7 Users Say Thank You to Nhoward For This Useful Post:

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  12. #48
    Breadmaker Shaker Plasnart's Avatar
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    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.

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  14. #49
    Patrol Guru Cremulator's Avatar
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    Quote Originally Posted by Plasnart View Post
    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.
    I agree!
    Congratulations, you can now download the manuals.

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  16. #50
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    Yeah wow Kudos to a job done well, bloody amazing can't wait to see hire she comes up

    Sent from my SM-G781B using Tapatalk

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