Old patrol roof rust repairs

[Nhoward]

Managed to get a whole lot done since the last update...

Fabricated this bit for the front left:
fiddly-bit.jpg

Welded in:
fiddly-bit-welded.jpg

Fabricated this bit for the rear left and welded it in:
back-left-welding.jpg

Cut the last roof patch piece and tacked it in:
tacking-last-piece.jpg

Welded up and ground back:
last-piece-in.jpg

Propped the roof up to get better access to some bits at the edges I needed to weld:
roof-up.jpg

Clamped up the front of the roof to the windscreen frame, welded it in, then ground it back:
windscreen-welded.jpg

Dropped the roof back down, and applied a ton of clamps and some straps:
fetch-the-clamps.jpg

Commence far too many plug welds:
plugging-away.jpg

End result: roof skin now bonded to body:
roof-attached.jpg

[Cremulator]

Great job

[happygu]

Great job ... a looootttt of work, but so awesome to see it done at home with minimal tools and amenities

[Nhoward]

Got some more done on the patrol...

Dragged this thing out of the depths of my storage are:
torch.JPG

Did the flux/bronze/fire thing and brazed the corners on:
brazed.jpg

Dressed the brazing and the plug welds from last time:
dressed.jpg

Flooded the gutters with a couple of tubes of POR15 seam sealer/filler (also sealed the underside) :
sealed.jpg

Once that lot cures, I have a couple of liters of cavity wax to blast in from the inside.

[budgie]

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