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So while in North Florida at my daughter's lacrosse tournament this weekend, I was able to score this roof section before the owner scrapped the cab.
My roof has about 2" of rust extending up from the drip rail above the passenger door for the length of the door. It also has pockets of rust between the front drip rail and the front windshield seal along the entire front. Sensing it will only be a matter of time before the rust erupts above the passenger door, was the reason I picked up this roof section. It has some surface rust and some "oil can" dents that push out but pop back down, but that's it. So my question is for those who have addressed roof rust:
Did you/would you replace the entire roof, of just surgically replace what was bad? If replacing the whole roof, what were your cut and splice points.
What is the best way of popping out the dents and keeping them out? (If I was to replace the whole roof?
If I was to cut out the drip rail, what is the method to attach the new one back? There doesn't seem to be a whole lotta metal to weld on to.
As usual - thanks in advance for any input you have. And before I irritate the Ford Gods by cutting this rood off - the cab was toast...floors gone, firewall non-existent, no doors, no glass...the rood metal was the only thing somewhat intact.
Great score on that roof. There are a few options as you have stated. The biggest one is to replace the roof entirely. I would start by cleaning up your roof and removing as much rust/rot. Once you have that you can see how bad your inner roof structure is. What is left will show you what needs to be done. If your inner structure is real good, sectioning the roof may be best. If the inner structure is bad, then replacing the roof may be required. The good thing is you got a lot of structure there to play with.
Ive only done floor pans before but if yours is rotted through, from the drip rail to the windshield, put the whole thing on. Sounds tedious, cutting and fitting 20 patches in total pain in the *** spots. Now I also dont know what the structure of the cab corners and window frame looks like inside. A picture of those would be good to see what is involved if it needs to be welded from the inside out. You could even cut some of the crap out of your cab then decide which is the better option.
Thanks Paul and 1Browski. I think the two of you are right: that peeling back the headliner and seeing how bad things are on the inside, will give me a better clue as to a course of action. Take a wheel to the rust and see how much comes off and what is left...oh my once pretty truck...
So in typical Geoff fashion, I may not have made the best purchase...The passenger side (the side really needed) looks ok, but upon closer inspection the drivers side has a sweep at the drip rail line, that I didn't notice when buying and chopping the thing. Looks like I'll be cutting sections instead of a whole roof replacement....great job, Geoffrey...
