this is the only real bad part of the cab, above and under the drip rail on the drivers side. I'm no body man by any means but here's where I'm at so far. still have some grinding and filler work to do. also have 2 small spots I think I may just fill, the metal is super thin around them and way to small to make a patch(at least for me,lol)

 

here's what's next

 

Subscribed cuz the LBB has roof rail rot too.

 

Looks good so far.

 

i'll be using a metal filler to finish it off. should only need about 1/16" (I hope) to level everything out. i'll finish it up next week after work.

 

No matter what, cut out all the rust! Even if you have to go with a bigger cut out panel. Remember is can always be worse.....

 

I hope i explain this right, first off your going in the right direction,kind of. If your not gonna replace the whole panel you need to cut out more and weld every single hole, even the smallest of holes. Using a metal body filler is not much better than a top brand name plastic body filler. Moisture, will find that hole and work down behind the filler and soon theres a bubble. All your money and time was wasted. Rust is a cancer to metal, its eating behind the panel where you cant see of get to, you can slow it but its eating its way threw. Over 30yrs in auto-body & welding and fab work, i always tried to stay away from working with rust unless new panels were going on. Shop around to see if you can find a roof from a Donner truck or find a fab shop and they can make a roof panel and replace the whole outer roof panel. Good luck with your build.

 

I have a friend who has been buying wrecked newer model cars for more than 40 years. He repairs them and sells them for hopefully a profit.He has probably 2-3 hundred thousand dollars worth of frame repair machinery.When he finishes a vehicle it looks better than brand new. I talked to him about doing some patch repairs on my old Bronco. He told me he would gladly help me if I buy new panels and change them out,but he wont cut out rust and weld in patches. Said his experience is you never get all the rust you cant see and it will come back. May be a year may be 4 years. But it always comes back.

 

Those patches look good so far!

Manufactured patch panels are nice but not always available. If not available weld in patches can work and last well. A few tricks to help. As mentioned, cut out all rust and replace. If you have to use lap joints, clean and treat with weld through primer first. When done, treat the backside of the repair. If you can get at it, rustoleum primer and paint is good. If not, spray or brush on waxy rust preventative. I use the Eastwood stuff. Smelly for a little while but good.

 

thanks guys for the comments. yeah I guess i'll cut a couple of small patches to take care of the two other spots. as far as replacing the whole roof, aint going to happen, this is the only part of the roof that's rotted. I por15'd what I could behind the cuts and used weld through primer. I did all butt joints, no lap joints.

 

Looks good John. I was going to ask what you were doing for the bare metal substructure but you beat me to it, POR-15.

 

Knock on wood here but luckily I haven't had to deal with roof rot so far.. I have a neighbor with a crew that has it bad up top.. good luck!

 

Correction, its the only place showing so far.

 

thanks guess i'll deal with the other rot when it appears.

 

had a little time, started the repair under the rail. above is what it looked like before. still need to finish it.