Old patrol roof rust repairs

[Nhoward]

Unfortunately life and Auckland weather have been getting in the way as of late, but I have managed to get a bit more done:

Time to do something about this oddly shaped hole where the A-Pillar connects to the roof frame...
dificult-hole.jpg

Cut up some patch plates and give them a shot of weld-thru:
primed-patches.jpg

Do a bunch of fiddly welding to rebuild the edge piece:
edge-rebuilt.jpg

Weld in the first part of the patch (had to call it a day at this point so I just fired some primer over it):
half-patched.jpg

Picking up where I left off, grind back the primer etc. and get ready for more patching:
hole-prepped.jpg

In with the next patch. This area has a join between panels, so I replicated that with my repair (overlap & plug welds):
patch-tacked-in.jpg

Weld everything up:
welded-up.jpg

Apply the finger sander, angle grinder and die grinder:
apply-grinder.jpg

Hide all that with some primer:
hide-sins.jpg

That's all the rust in the driver's door are repaired, on to the rear end.
Tack in the patches:
patch-tacked.jpg
rear-tacked.jpg

Some more welding...
rear-welded.jpg

Add some primer:
rear-painted.jpg

Just need to finish off the back right corner, then the drivers side frame repairs will be complete.