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Thread: Old patrol roof rust repairs

  1. #21
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    Quote Originally Posted by PureCaboose View Post
    It's amazing how much time we don't have when in quarantine (not that it changed anything for us, if anything we go out more. sigh)
    Yup... I work in IT so I am able to work from home pretty easily. Combine that with a senior management team that are bored senseless as a result of the lockdown, and it's very easy to get buried in more work than you would have otherwise.

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  3. #22
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    Some more progress...

    Finished welding in and grinding back a patch:
    groundback.jpg

    Complete with some primer:
    patchpainte.jpg

    Marked out some steel:
    markup.jpg

    Then chopped it up:
    chopped.jpg

    I did three of these in total, then ran them through the bender and welded them end to end.
    The end result is too long to easily take a photo of, but it should be welded to the side of the frame rail in due course.

    Cleaned up the rear of the thing - removed what remained of the rear gutter and marked out the bit I need to cut out and patch:
    rrrust.jpg

    I ground off the rust in the good areas and gave them a shot of primer, but it was too dark to get a good photo.

    The next task is the back corner. A bit rusty...
    rrcorner.jpg

    I'll have to fabricate and weld in a temporary support for the roof frame before I chop that lot out.
    Attached Images Attached Images

  4. The Following 2 Users Say Thank You to Nhoward For This Useful Post:

    0-TJ-0 (18th May 2020), Sherro (16th May 2020)

  5. #23
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    You are amazing, brilliant work, top stuff
    Manufacturer of the Complete Camp Oven System

    Website:http://davesstuff.net/

    Vendor Page: http://www.nissanpatrol.com.au/forum...ar-That-Works/

    Tuturial Video's: http://www.nissanpatrol.com.au/forum...ted-on-Youtube

  6. #24
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    Time to do something about the rear right corner of this thing...

    Welded in some temporary support struts:
    temporarysupports.jpg

    Removed the rusted bit of the existing support, removed the remains of the gutter and marked out the intended path of the body saw:
    gutterectomy.jpg

    Marked out the cut on the rear:
    problem-circled.jpg

    A few moments with the body saw... no more rust, but some big holes to patch:
    rear-rustectomy.jpg
    side-rustectomy.jpg

    Test fitted the gutter I fabricated earlier:
    gutter-testfit.jpg

    Needs to be another 250mm longer, but looks like it'll work.

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

    0-TJ-0 (18th May 2020), Cremulator (9th July 2020), mudnut (18th May 2020), MudRunnerTD (22nd February 2021), oxmann (9th July 2020), Rossco (17th May 2020)

  8. #25
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    How is your project coming along ? would love to see some more updates.I have just started doing this to my "92 GQ patrol" not as bad as yours, but still needs doing....and your pics,ideas etc are excellent.I see you are in NZ as I am,where abouts ?? Anyway thanks for your project updates,would love to see some more....cheers

  9. #26
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    Some overdue progress...

    Unfortunately life and Auckland weather have been getting in the way as of late, but I have managed to get a bit more done:

    Time to do something about this oddly shaped hole where the A-Pillar connects to the roof frame...
    dificult-hole.jpg

    Cut up some patch plates and give them a shot of weld-thru:
    primed-patches.jpg

    Do a bunch of fiddly welding to rebuild the edge piece:
    edge-rebuilt.jpg

    Weld in the first part of the patch (had to call it a day at this point so I just fired some primer over it):
    half-patched.jpg

    Picking up where I left off, grind back the primer etc. and get ready for more patching:
    hole-prepped.jpg

    In with the next patch. This area has a join between panels, so I replicated that with my repair (overlap & plug welds):
    patch-tacked-in.jpg

    Weld everything up:
    welded-up.jpg

    Apply the finger sander, angle grinder and die grinder:
    apply-grinder.jpg

    Hide all that with some primer:
    hide-sins.jpg

    That's all the rust in the driver's door are repaired, on to the rear end.
    Tack in the patches:
    patch-tacked.jpg
    rear-tacked.jpg

    Some more welding...
    rear-welded.jpg

    Add some primer:
    rear-painted.jpg

    Just need to finish off the back right corner, then the drivers side frame repairs will be complete.

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

    0-TJ-0 (25th July 2020), Cremulator (26th July 2020), mudnut (25th July 2020), Plasnart (25th July 2020), Rossco (25th July 2020), Sherro (25th July 2020)

  11. #27
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    More cutting and welding...

    Got this weirdly shaped rusty area on the right rear corner to sort out:
    rusty-corner.jpg

    Made up a patch using a paper template:
    tricky-patch.jpg

    Tacked in place:
    tricky-patch-tacked.jpg

    Welded in:
    tricky-patch-welded.jpg

    Hit with the grindy tools:
    corner-grindback.jpg

    Quick squirt of weld-thr:
    corner-painted.jpg

    Now for this one... As it was originally where two panels overlap and join, this was a little more complicated.
    rear-hole.jpg

    Weld in the first patch:
    patch1-welded.jpg

    Grind it flush:
    patch1-ground.jpg

    Stick the second patch over the top:
    patch2-tacked.jpg

    Weld it in:
    patch2-welded.jpg

    Grind it back:
    patch2-groundback.jpg

    Apply paint:
    rear-painted.jpg

    With this bit done, I can now say that the driver's side roof frame is rust free!

    Next is to fabricate and weld on a new gutter, then do something about the roof support framework that is currently hanging mid-air.

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

    0-TJ-0 (26th July 2020), Cremulator (26th July 2020), MB (6th August 2020), mudnut (26th July 2020), Plasnart (26th July 2020), Sherro (26th July 2020)

  13. #28
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    Driver's side gutter time

    Managed to get the driver's side gutter completed and on the truck.

    Fabricate the last piece that fits at the front:
    rail-end.jpg

    Weld it on the bit I made earlier, grind it back and paint it:
    rail-painted.jpg

    Spend quite a long time doing many, many plug welds:
    bulk-plugwelds.jpg

    Almost there (welding up the front at this point)
    almost-there.jpg

    Gutter attached:
    complete.jpg

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

    0-TJ-0 (8th August 2020), Cremulator (6th August 2020), MB (6th August 2020), MudRunnerTD (22nd February 2021), Plasnart (6th August 2020), Rossco (21st August 2020), TimE (6th August 2020)

  15. #29
    Patrol Guru TimE's Avatar
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    I admire your skills and patience
    Time Marches On .....and on ..... and on

  16. #30
    Patrol God mudnut's Avatar
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    Looking good.

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