Old patrol roof rust repairs

[Nhoward]

Amazing work mate. My GQ had the dreaded roof rust, after doing one semi-dodgy repair and having it rear its head again with vengeance ended up getting a new shell and doing a cab swap. Once it starts popping up on the outside you know it's pretty bad in there. . . Good luck looks like fun can't wait to see how it comes up.

I toyed with the idea of swapping the shell or grafting on a donor roof, but I have very little chance of finding either in good condition over here in NZ. Our humid climate and day/night temperature swings are excellent at causing the condensation that causes these 4x4s to rust from the inside out.

Many of the issues I am dealing with are as a result of dodgy repairs that were done to get the thing through it's next inspection - steel patches welded in with no rust proofing, RTV sealant masquerading as a roof gutter etc.

I payed $1000 for the patrol, so I had some idea what I was getting in to. I figure it doesn't really owe me anything, and worse case scenario I have to scrap it after I have learned a whole bunch about doing bodywork on a 4x4.
Best case scenario I fix all the rust and drive the thing for several more years.

I'll update this thread as I continue to hack away at the thing. Fortunately I have a MIG, an air body saw, and an angle grinder - and I'm not afraid to use them!