Old patrol roof rust repairs

[Nhoward]

Got a bit more done on this project.
Unfortunately I was rushing against an incoming storm so I did not take too many photos.

Mark out some steel that will become the end of the roof frame support...
steel-origami.jpg

Use a combination of a sheet metal bender and some hammers to fold it up
folded-up.jpg

All three bits welded in and primed - the roof frame is no longer hanging in mid-air.
welded-in.jpg

With that, the driver's side is done! Now to do the same process on the other side...

[Nhoward]

I'll mention the photo makes it obvious why these vehicles rust from the inside out.

the roof is attached to the top of the gutter, leaving a void between the roof skin and the roof frame for moisture to accumulate.
The rust proofing in this area also appears to be sub optimal - paint does not seem to make it down in to the void during manufacture, so we are just left with the phosphate coating to protect the underlying steel.

My current theory on the corrosion is condensation forms on the inside of the roof, runs down the inside and pools in the void, with nowhere to go.

In order to prevent the roof rusting out again any time soon, I am planning to insulate the inside of the roof skin with dynamat or similar, inject something like two-pack stone chip paint into the void between the frame and the roof skin, and drill some drainage holes in the gutter so that any moisture that accumulates has somewhere to escape.

[0-TJ-0]

Always happy when I see your thread pop up with a new update. Satisfying watching it come together mate, good job.

[Nhoward]

Had the first weekend with good weather in a while so I got the tools out and pressed on with the patrol repairs...

Started drilling out many spot welds holding the rusty gutter on:
rusty-gutter.jpg

Started chopping some of the gutter out:
begin-gutterectomy.jpg

Welded in some temporary supports for the roof frame, marked the ends of the roof frame that need to go, and started cutting:
marked-and-cutting.jpg

Stripped off the rusted mess that was once the passenger side gutter:
gutter-gone.jpg

Hauled out the old oxy-acetalyne rig and used that to get the old braze off the corners.
Kind of scary holding the torch in one hand and the drill with the wire wheel in the other, and playing "dodge the flying molten metal" but it came up well:
braze-removed.jpg

Went at what remained with the wire wheel, the stripping disk and the sanders:
derusted.jpg

After that was done I gave the area a wipe down with some rust converter to catch anything I missed with the power tools and called it a day.

[Nhoward]

Got the passenger side finished off.

Started with this:
side_primed.jpg

Cut out some steel sections
steel-chunks.jpg

Persuaded them into the shape I wanted with this contraption (yes, that's a sheet metal folder clamped to my kitchen bench):
kitchen-bending.jpg

Ended up with three of these:
rail-sectiopns.jpg

Welded them end to end and test fitted:
test-fit.jpg

Finished it off, drilled a bunch of holes and clamped it to the truck>
clamp-on.jpg

Spent far too long making far too many plug welds:
many-many-many-plugwelds.jpg

All welded up:
gutter-welded.jpg

Welded on some new roof frame support brackets I bent up, ground back all the welds and gave it a shot of rustkill paint:
painted.jpg

Now I have to sort out the not insubstantial rust in the roof support frame, then it's on to the roof skin itself.

[Nhoward]

I know it's been several months since I have updated this thread, but the project is still ongoing.

So... what have I been up to?


Welded up a ton of rivet holes on the sheet of steel that used to be over the sunroof:
well-rivet-holes.jpg

Flipped the roof over:
inside-root.jpg

Started tacking:
mega-tackjob.jpg

Back over it goes to begin a very long, slow stitch welding job:
start-stitch-welding.jpg

Gave it a whack of etch primer:
welded-primed.jpg

Chopped all this rusty junk off the edges:
edges-off.jpg

Ground off the last of the rust in the roof support frame:
rust-begone.jpg

Last patch going in to the roof support frame:
last-patches.jpg

All coated in rustkill paint:
roof-subframe-done.jpg
blackification.jpg

Started building this support to bridge the gap and reinforce the roof frame where the sunroof used to mount:
new-support.jpg
finishing-support.jpg

Plug welded both ends in:
plugwelded.jpg

Gave it the usual rustkill treatment:
painted-black.jpg

Left it to dry for a few hours, then dropped the roof on top:
roof-on.jpg
roof-on-inside.jpg

Next is the fun task of welding in strips on all sides to fill the air gap, then plug welding them to the gutters.

Also found this mess lurking under a tin's worth of filler:
new-mess.jpg

Should be straightforward after what I've done so far.

[PeeBee]

Was wondering where you have been? Great job, loving this build. Brilliant documentary also. thanks

[Plasnart]

Great to see you back NH. This is such a great thread, love your work mate! Can't get enough of skilled panel work and so well presented.

[MudRunnerTD]

Looking great mate. I too rebuilt a GQ in the back yard and used one of those White Tents. it got it done but loving a Shed now. I had the tent set up and the car fully prepped for paint. masked up and rubbed back, washed down with wax and grease remover and ready to go...... Got up at 7am the next morning for Paint and it was blowing a bloody gail from over the side fence and it got up and under the tent and destroyed it.... On Paint Day! Hours and Days of prep was gone. Was a very shit day. i was gutted. i could just sit and look at it.

Your project s coming up a treat mate. a Credit to you.

[Intrinsic]

I just bought a 1980 MQ that has what appears to be a couple small rust sections in the roof at the gutter line (as well as the door corners but that should be easy). I was thinking an easy fix, but after seeing what happened to this one I am dreeding to see what lurks behind. I can only hope that it is not as bad as that