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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

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    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.

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    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 7 Users Say Thank You to Nhoward For This Useful Post:

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