Hi guys I was doing some cleaning with the wire wheel and exposed this on the roof line...how would or should this,be fixed. Any tips or suggestions.
It's on a 56 f100

 

It looks like it can be patched. Its pretty small. I'm no expert but I'm sure they will be along soon.

 

Keep going around as you'll probably find more

 

That can be patched. Cut out the rusted section in a semi oval arc and cut out a matching patch out of metal of the same thickness and bend to shape. Be careful not to cut too deep. The reason I would make an 'arch' cut is because I find it neater to weld when there isn't corners. I would spot weld a nail to the patch to hold it place if you can't acccess from behind. Spot weld the patch in place and grind off the nail. This is probably the way I would do it but others I'm sure will be along with their methods.

 

Here is the "correct" way...Metal Finishing and Rust Repair
Now that you know the right way, you may find that your pockets are not quite that deep, somewhere in the neighborhood of $6K, so it will be up to you to choose what works best for your truck and your wallet. When I do these repairs I cut out any portion of the roof skin that has rot and weld in new metal. The inner channel, the part you can see through the hole, is usually also rusted. I have found that this rust can be treated by wire brushing and blowing out channel to remove all loose material. I use Rust Seal, a rust encapsulating paint, to thoroughly coat this channel and the underside of the roof skin in this area. To show you how poorly the seams are sealed from the factory, take a look at this photo...this is my cab that I sealed the inside channel on. The black seeping through the seam is the Rust Seal. This is the reason these cabs rust in the roof seams, they are not weather tight.

 

Wow that's f**ked up
thanks for the tips

 

You probably would find more of that if you started looking. Know that it is rusting from the inside. It's from condensation on the inside of the roof skin running down to the metal that makes up the front window frame. Whichever way that you intend to repair it, spend some time applying effective corrosion-proofing as much as you can on the other side.

 

I ran into the same problem with the cab I'm working on now, like was said don't be surprised to find more. I replaced the metal all around my roof top, think there is pics in my build thread.

 

Yep I patch mine but there right there usually is more

 

Take your time dont get overwhelmed and shape your metal to the bend. Once you have the first piece the others will be easy.

 

You are an awesome metal worker saw how you did the roof line nice...I'm going to try and attempt it. Stay tuned.
Thanks again for the help