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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.Quote:
Originally Posted by Intrinsic
You'll have to pull the headliner and have a look in the cavity to be sure.
Best of luck!
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.
I agree!Quote:
Originally Posted by Plasnart
Congratulations, you can now download the manuals.
[emoji23]
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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Managed to get a whole lot done since the last update...
Fabricated this bit for the front left:
Attachment 84399
Welded in:
Attachment 84400
Fabricated this bit for the rear left and welded it in:
Attachment 84401
Cut the last roof patch piece and tacked it in:
Attachment 84402
Welded up and ground back:
Attachment 84403
Propped the roof up to get better access to some bits at the edges I needed to weld:
Attachment 84404
Clamped up the front of the roof to the windscreen frame, welded it in, then ground it back:
Attachment 84405
Dropped the roof back down, and applied a ton of clamps and some straps:
Attachment 84406
Commence far too many plug welds:
Attachment 84407
End result: roof skin now bonded to body:
Attachment 84408
Great job [emoji108]
Great job ... a looootttt of work, but so awesome to see it done at home with minimal tools and amenities
Got some more done on the patrol...
Dragged this thing out of the depths of my storage are:
Attachment 84430
Did the flux/bronze/fire thing and brazed the corners on:
Attachment 84431
Dressed the brazing and the plug welds from last time:
Attachment 84432
Flooded the gutters with a couple of tubes of POR15 seam sealer/filler (also sealed the underside) :
Attachment 84433
Once that lot cures, I have a couple of liters of cavity wax to blast in from the inside.
Hey mate great thread!
I will be starting my roof in the next month, although mine isn't as bad but i did find a whole roof that was cut at the pillars as a spare and will be replacing the whole roof skin as well as cutting sections out and using the spare panels i have!
i haven't had much time to strip my spare roof back Ive only stripped back the silicon in the gutters and rubbed the paint back where the brazing is.
couple quick ones for ya,
Q1 What size spot weld drill bit did you use? i bought a 6mm Sutton one but i think its to small maybe a 8 or 10mm might be better?
Q2 I noticed you got an oxy set up to melt away the bronze. i haven't even looked into a oxy set up so don't know the costs and if its worth it. maybe a small grinder might work?
Q3 Also why did you bronze the corners like they are originally in your last post and just not mig them up?
Ill most likely have more questions later on haha but don't want to pester you with a whole bunch!
Good thread its defiantly giving me more courage to do mine and although mine is my daily i have some time over xmas to do it so hopfully i can get it done!
Cheers,
budgie