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Thread: Old patrol roof rust repairs

  1. #11
    Expert Deano2506's Avatar
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    Best post I've seen on here in a long time.great looking work too.
    Keep up the updates mate

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  3. #12
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    Q&A

    Figured I would answer some of the questions you guys are asking...

    I left the seats in because they are already rather tired/stained/ratty so I'm not worried about the odd burn mark (and I don't currently have anywhere else to put them)
    I am however protecting the interior from weld splatter as best I can using a mixture of wet old bedsheets and spare steel panels that I wedge between what I'm welding and the interior.

    I'm using the side panels from some server racks that we decommissioned at work as the donor steel. It's the right thickness and I have a pile of them.
    I'm hand shaping the steel at the moment - lacking a sheet metal bender I'm afraid. The usual process is to clamp the steel to a large chunk of angle iron, then bash it with a hammer until it looks about right.

    A donor car would be handy to chop bits out of, however finding one without any rust in the roof would be tricky. All the patrols I have seen at wreckers have visible rust in the roof area, and even if I find one without visible rust, I won't know its condition until I haul it home and yank the roof skin off. At this juncture, I think it's a better/easier option to just fix the rust in what I've got.

    At this point it's unfortunately a slow project. I can only really work on it during the day on weekends, when it's not raining, and at reasonable times so I don't drive my neighbours insane with the dulcet tones of air compressors, saws and grinders.

  4. The Following 3 Users Say Thank You to Nhoward For This Useful Post:

    Cremulator (19th March 2020), mudnut (23rd March 2020), MudRunnerTD (19th March 2020)

  5. #13
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    slowly slowly...

    Got some more done:

    Cleaned up this bit where the frame had rusted out:
    siderail.jpg

    Chopped a rusty bit out of the B-Pillar:
    b-pillar-hole.jpg

    measured up and chopped off a piece of server panel that had a convenient 100* bend in it and tacked it in to place:
    rail-tacked.jpg

    Started welding it up. Doing a little bit at a time so that nothing gets too badly warped:
    rail-stitched.jpg

    Finished welding and started grinding:
    rail-groundback.jpg

    Gave it a shot of primer:
    rail-painted.jpg

    On to that hole in the B-pillar.
    One CAD template transferred to steel:
    template-transfered.jpg

    Chopped out and ground the paint off the edges:
    cut-grind.jpg

    Apply some dodgy bending methodology:
    outback-bender.jpg

    Tack it in place:
    b-pillar-tacked.jpg

    Finesse it with a large hammer, and weld it in:
    b-pillar-welded.jpg

    Go nuts with the flap disk:
    b-pillar.jpg

    Not bad for a Saturday afternoon. Once piece at a time.
    With the country going in to covid19 lockdown on Wednesday, the upside may well be more time to work on this thing!

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

    0-TJ-0 (24th March 2020), Cremulator (24th March 2020), MB TD42 (24th March 2020), mudnut (23rd March 2020), PeeBee (24th March 2020), Sherro (10th May 2020), Touses (24th March 2020)

  7. #14
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    A little more progress

    I'm trying to be nice to the neighbors during lockdown, so I have not been working on the Patrol much.
    I have made a bit of progress though;

    A couple of patches coated in weld-thru primer drying in the sun:
    painted.jpg

    Tacked in:
    also-tacked.jpg
    tacked.jpg

    Welding up:
    welding-in.jpg

    Welded up:
    full-welded.jpg

    Flatteneing off:
    grindback.jpg

    Then rinse and repeat with another patch:
    tacked.jpg
    stiching-up.jpg
    fullweld.jpg
    welded.jpg

    At this point I was rapidly running out of daylight so I called it a night.

    Progress is still slow, but the driver's side of the truck is now more metal than rust and air.

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

    0-TJ-0 (12th April 2020), Cremulator (11th April 2020), mudnut (11th April 2020), MudRunnerTD (22nd February 2021), PeeBee (11th April 2020), Plasnart (11th April 2020), Rossco (11th April 2020), Sherro (12th April 2020)

  9. #15
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    A short update...

    between the covid lockdown and a few weeks of bad weather I have not managed to get too much done, but I have made some progress;

    Chopped out a big chunk around the B-pillar:
    b-pillar-hole.jpg

    cut out and bent up some patch plates:
    b-pillar-patches.jpg

    Spent an afternoon playing metal tetris:
    metal-tetris.jpg

    Got it all welded in (and most of it ground back & painted):
    b-pillar-patched.jpg

    On to the next problem... quite a bit of rust on the A-pillar:
    next-problem.jpg

    A problem easily solved with the air body saw...
    rustectomy.jpg

    That did leave quite a bit, oddly shaped hole though

    For my next challenge, I need to make the piece on the left look like the one on the right (minus the rust):
    challenge.jpg

    While I was tearing some of that apart it did make me wonder - do any of you lot know why the roof skin and gutters are brazed on at the corners?
    I'm hoping it was done for ease/speed of assembly but I'm not 100% sure.

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    0-TJ-0 (11th May 2020), Plasnart (12th May 2020), Rossco (11th May 2020), Sherro (10th May 2020)

  11. #16
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    Right... time to something about that hole...

    Use some paper to make a template, then trace the result on to some steel:
    templatentraced.jpg

    Cut it out, stuck it in a bender then bash it with a hammer (or 3):
    cutandbent.jpg

    Sand it back and drill some holes in it for plug welds (I did paint the back of it with weld-thru primer):
    sandeddrilled.jpg

    Weld in the plug welds, tack some of it place then align it to final shape by bashing it with a hammer some more:
    tacknwhack.jpg

    Weld it up, then grind it back:
    grind.jpg

    Give it a coat of weld-thru primer:
    paint.jpg

    Got this other patch tacked in, then ran out of daylight:
    patchtack.jpg

    I'm getting tantalizingly close to finishing off this frame rail.

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

    0-TJ-0 (13th May 2020), Cremulator (11th May 2020), jack (11th May 2020), mudnut (11th May 2020), MudRunnerTD (22nd February 2021), PeeBee (11th May 2020), Plasnart (12th May 2020), Rossco (11th May 2020)

  13. #17
    Legendary Rossco's Avatar
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    Love your work mate keep it com'n. She's looking good can't wait to see how it comes up

    Sent from my SM-G930F using Tapatalk

  14. #18
    Breadmaker Shaker Plasnart's Avatar
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    Yep this is a bloody tops thread. Loving it @Nhoward Brilliant work so far mate, keep it going.

  15. #19
    Patrol God mudnut's Avatar
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    You have the patience of a saint. Top work.
    Last edited by mudnut; 11th May 2020 at 11:49 PM.

  16. #20
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    I love your work, I am so limited in what I can do in my workshop at the moment due to all the joeys in care...can't even finish putting the engine back together.

    Great to see someone repairing rather than just throwing away a lovely old truck.

    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)
    Greg Pointing
    Conservation, Rehabilitation & Education
    1989 GQ Patrol Wagon, TB42 Auto - Now with 2" of added lift...
    1991 Mazda MX5 - Coilovers, Exhaust, Intake, NB brakes & seats.
    2012 Mitsubishi Triton 4x4 Dual cab TDI - The Mrs truck....

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