PROGRESS REPORT
Please ignore all the mud and dust .. I don't want to wash it until I have primed any bare metal areas. I know this should have already done, but spare time is a bit limited these days.
To reiterate .. my intentions are to repair the vehicle to a 'reasonably clean' condition on a budget. My reasons for this are purely based on this being a 20yo vehicle that only gets used for camping and 4x4'ing. Damage is inevitable within reason (hopefully no more rollovers!). I had only recently installed a newer low-km engine and frequently maintain it .. so it's a reliable old bus.
I am happy with the results of the roof straightening. All cross-dimensions are now perfectly square. Hydraulic jack and a length 90x35mm structural pine did the trick. I had to make a base to hold the jack on the correct angle with the force vector. This method gave a very controlled force (thanks to 04OFF for the suggestion). New window & rubber fitted with no problems.
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LHS: Looking a little better now. Snorkel straightened with the use of a heat gun. Gutter still requires attention. Damage to the rear panel; not sure what to do with this. I'll shop around for a good panel beater quote.
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RHS: RR door has now been replaced. It's a good match, even the dust matches. Rear panels are undamaged. Front guard removed, and waiting for the replacement. Drivers door was actually pushed in on the day, but popped out on its own accord during recovery. It seems to be okay so I won't bother replacing it at this stage. Roof gutter requires attention.
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Front Guard: The damaged panel before removal. I had to cut off the brush-bar to remove the panel. The brush bar had bent up into the panel, so either way needed to be cut off and straightened. At a later stage I'll fabricate a joint that allows to bolt-on the brush-bar at both ends. Wheel arch flare had all the lugs ripped off.
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Front Guard: The damaged panel removed. No damage underneath.
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LHS Roof: With a few good kicks, the roof popped out to achieve the general roof shape. The roof-rack left a few dents. My theory is that the full-length roof rack distributed the load on the roof, therefore minimising any point-force loads. At this stage I will just clean up the damaged paint, and re-spray these areas. The snorkel appears on an angle, but only because I haven't reinstalled the pillar bracket.
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RHS Roof: Similar to the other side .. symmetrical damage
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LHS Rear Damage: This was the damage mentioned earlier. It's a pity I can't just unbolt this panel and replace it. In this state it's going to make it difficult to refit the arch flare. I know there are rubber flares available, I just prefer the plastic ones.
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In my opinion, I think the Patrol sustained surprising little damage considering to the 2 rolls down the hill. Very lucky .. but I'm more grateful that we were uninjured.
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